

Service Manual

Wheeled Loading Shovel - 426, 436, 446

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803-4160-15



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

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

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i-0 9803-4160-15 i-0

 
Section 1

General Information
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-12



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section 1 - General Information

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1-0 9803/4160-12 1-0

 Section 1 - General Information

Contents Page No.

Introduction
About this Publication .............................................................................. 1 - 1

Identifying your Machine

Identification Plates ................................................................................. 1-2
Identification Plate .............................................................................. 1-2
Explanation of Vehicle Identification Number (VIN) ............................ 1-2
Unit Identification ................................................................................ 1-2
Typical Engine Identification Number ................................................. 1-2

Torque Settings
Zinc Plated Fasteners (golden finish) ...................................................... 1-4
UNF Grade `S' Bolts ........................................................................... 1-4
Metric Grade 8.8 Bolts ........................................................................ 1-4
Rivet Nut Bolts/Screws ....................................................................... 1-4

Service Tools
Numerical List Section B - Body and Framework .................................... 1 - 5
Tool Detail Reference Section B - Body and Framework ........................ 1 - 6
Numerical List Section C - Electrics ........................................................ 1 - 9
Tool Detail Reference Section C - Electrics ........................................... 1 - 10
Numerical List Section E - Hydraulics ................................................... 1 - 12
Tool Detail Reference Section E- Hydraulics ......................................... 1 - 15
Numerical List Section F - Transmission ............................................... 1 - 18
Tool Detail Reference Section F - Transmission .................................... 1 - 19
Numerical List Section K - Engine ......................................................... 1 - 22
Tool Detail Reference Section K - Engine ............................................. 1 - 23

Service Consumables
Sealing and Retaining Compounds ....................................................... 1 - 24

1-i 1-i
 Section 1 - General Information

Contents Page No.

1 - ii 1 - ii
 Section 1 - General Information

Introduction
About this Publication

This publication is designed for the benefit of JCB All sections are listed on the front cover; tabbed divider
Distributor Service Engineers who are receiving, or have cards align directly with individual sections on the front
received, training by JCB Technical Training Department. cover for rapid reference.

These personnel should have a sound knowledge of Where a torque setting is given as a single figure it may be
workshop practice, safety procedures, and general varied by plus or minus 3%. Torque figures indicated are
techniques associated with the maintenance and repair of for dry threads, hence for lubricated threads may be
hydraulic earthmoving equipment. reduced by one third.

Renewal of oil seals, gaskets, etc., and any component 'Left Hand' and 'Right Hand' are as viewed from the rear of
showing obvious signs of wear or damage is expected as the machine facing forwards.
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any This Service Manual covers the following machines:
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt. 426 Wheeled Loading Shovel from machine serial number
Finally, please remember above all else SAFETY MUST 531001
COME FIRST!
436 Wheeled Loading Shovel from machine serial number
The manual is compiled in sections, the first three are 533001
numbered and contain information as follows:
446 Wheeled Loading Shovel from machine serial number
1 General Information - includes torque settings and 540000 to 540011
service tools.
Note: The information provided in this manual for the 436
2 Care & Safety - includes warnings and cautions machine also applies to the 446 machine, except where
pertinent to aspects of workshop procedures etc. specified.

3 Routine Maintenance - includes service schedules Note: USA ONLY - For 426 machines built after November
and recommended lubricants for all the machine. 1998, Hydraulic and Electrical Information is as for 436
machines. Also, machine serial numbers start at 544001.
The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for Note: USA ONLY - For 426 machines built after October
example: 2000, Hydraulic and Electrical Information is as for 426
machines. Also, machine serial numbers revert to the
normal 426 series.
A Attachments
B Body & Framework...etc.

The page numbering in each alphabetically coded section

is not continuous. This allows for the insertion of new items
in later issues of the manual.

Section contents, technical data, circuit descriptions,

operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.

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 Section 1 - General Information

Identifying your Machine

Identification Plates

Identification Plate The machine and engine serial numbers can help identify
exactly the type of equipment you have.
Your machine has an identification plate 1X mounted on
the left hand side of the machine. The serial numbers of Unit Identification
the machine and its major units are stamped on the plate.
The engine serial number is stamped on a plate 2Y which
is fastened to the right side of the cylinder block, near the
fuel filter.

Fig 1.

Explanation of Vehicle Identification

Number (VIN)

1 2 3 4 5
SLP 42600 S E 0531001
Fig 2.
1 World Manufacturer Identification, SLP = JCB
Typical Engine Identification Number
2 Machine Model, 42600 = 426
1 2 3 4 5
3 Year of Manufacture S, (P = 1993, R = 1994, S =
1995, T = 1996, V = 1997, W = 1998, X = 1999, Y = YB 50457 U 576887 Y
2000, 1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004)
1 Engine Type, YB = 6 cylinder turbo
4 Manufacturing Location (E = England)
2 Build Number
5 Machine Serial Number (0531001)
3 Country of Origin
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the 4 Engine Sequence Number
serial number on the identification plate will be wrong.
Either stamp the new number of the unit on the 5 Year of Manufacture
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when The Transmission serial number is stamped on plate 3Z as
replacement parts are ordered. shown.

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 Section 1 - General Information
Identifying your Machine
Identification Plates

Fig 3.

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 Section 1 - General Information

Torque Settings
Zinc Plated Fasteners (golden finish)

Use only where no torque setting is specified in the text. Metric Grade 8.8 Bolts
Values are for dry threads and may be within three per cent
of the figures stated. For lubricated threads the values
should be REDUCED by one third. Bolt size Torque Settings
Dia. (mm) Hexagon Nm kgf m lbf ft
UNF Grade `S' Bolts (A/F) mm
M5 (5) 8 7 0.7 5
Bolt size Torque Settings
M6 (6) 10 12 1.2 9
Dia. (mm) Hexagon Nm kgf m lbf ft
M8 (8) 13 28 3.0 21
(A/F) mm
M10 (10) 17 56 5.7 42
1/4 6.3 7/16 14 1.4 10
M12 (12) 19 98 10 72
5/16 7.9 1/2 28 2.8 20
M16 (16) 24 244 25 180
3/8 9.5 9/16 49 5.0 36
M18 (18) 27 350 36 258
7/16 11.1 5/8 78 8.0 58
M20 (20) 30 476 48 352
1/2 12.7 3/4 117 12.0 87
M24 (24) 36 822 84 607
9/16 14.3 13/16 170 17.3 125
M30 (30) 46 1633 166 1205
5/8 15.9 15/16 238 24.3 175
M36 (36) 55 2854 291 2105
3/4 19 1 1/8 407 41.5 300
7/8 22.2 1 5/16 650 66.3 480 Rivet Nut Bolts/Screws
1 25.4 1 1/2 970 99.0 715
1 1/4 31.7 1 7/8 1940 198.0 1430 Bolt size Torque Settings (for
steel rivet nuts)
1 1/2 38.1 2 1/4 3390 345.0 2500
Dia. (mm) Nm kgf m lbf ft

M3 (3) 1.2 0.12 0.9

M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.

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 Section 1 - General Information

Service Tools
Numerical List Section B - Body and Framework

The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is
removal and replacement of Body and Framework parts. expected that such general tools will be available in any
These tools are available from JCB Service. well equipped workshop or be available locally from any
good tool supplier.

Part Description Tool Detail

Number Reference
825/99849 Dummy Bush Fig 12. ( 1-8)
825/99851 Bearing Locator Fig 12. ( 1-8)
826/01179 M6 x 16mm Rivet Nut Fig 1. ( 1-6)
826/01106 M6 x 19mm Rivet Nut Fig 1. ( 1-6)
826/01177 M8 x 18mm Rivet Nut Fig 1. ( 1-6)
826/01176 M10 x 23mm Rivet Nut Fig 1. ( 1-6)
826/01333 M10 x 26mm Rivet Nut Fig 1. ( 1-6)
892/00842 Glass Lifter Fig 3. ( 1-6)
892/00843 Glass Stand Fig 2. ( 1-6)
892/00844 Long Knife Fig 11. ( 1-8)
892/00846 Glass Extractor (Handles) Fig 8. ( 1-7)
892/00847 Nylon Spatula Fig 4. ( 1-6)
892/00848 Wire Starter Fig 6. ( 1-7)
892/00849 Braided Cutting Wire Fig 10. ( 1-8)
926/15500 Rubber Spacer Blocks Fig 5. ( 1-7)
992/12800 Cut-Out Knife Fig 7. ( 1-7)
992/12801 'L' Blades Fig 9. ( 1-8)

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 Section 1 - General Information
Service Tools
Tool Detail Reference Section B - Body and Framework

Tool Detail Reference Section B - Body and Framework

Note: essential for preparing new glass prior to

installation.

Fig 1.
Fig 3. 892/00842
Note: 826/01179 M6 x 16mm Rivet Nut, 826/01106 M6
Note: - minimum 2 off - essential for glass installation, 2
x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut,
required to handle large panes of glass. Ensure suction
826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x
cups are protected from damage during storage.
26mm Rivet Nut
Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW

Fig 4. 892/00847
Note: - general tool used for smoothing sealants - also
used to re-install glass in rubber glazing because metal
tools will chip the glass edge.

Fig 2. 892/00843

1-6 9803/4160-12 1-6

 Section 1 - General Information
Service Tools
Tool Detail Reference Section B - Body and Framework

Fig 5. 926/15500
Fig 7. 992/12800
Note: - used to provide the correct set clearance
between glass edge and cab frame. (unit quantity = 500 Note: - used to remove broken glass.
off)

Fig 8. 892/00846
Note: - used with braided cutting wire (below) to cut out
broken glass.

Fig 6. 892/00848
Note: - used to access braided cutting wire (below)
through original polyurethane seal.

1-7 9803/4160-12 1-7

 Section 1 - General Information
Service Tools
Tool Detail Reference Section B - Body and Framework

Fig 9. 992/12801
Note: - 25 mm (1 in) cut - replacement blades for cut-out
knife (above), (unit quantity = 5 off)

Fig 12. 825/99849

Note: - used with bearing locator to set up Upper Centre
Pivot.

Fig 10. 892/00849

Note: - consumable heavy duty cut-out wire used with
the glass extraction tool (above), (approx 25 m length)

Fig 13. 825/99851

Note: - used with dummy bush to set up Upper Centre
Pivot.

Fig 11. 892/00844

Note: - used to give extended reach for normally
inaccessible areas.

1-8 9803/4160-12 1-8

 Section 1 - General Information
Service Tools
Numerical List Section C - Electrics

Numerical List Section C - Electrics

The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is
testing electrics. These tools are available from JCB expected that such general tools will be available in any
Service. well equipped workshop or be available locally from any
good tool supplier.

Part Description Tool Detail

Number Reference
718/20237 Interrogation Lead Fig 18. ( 1-11)
892/00282 Shunt Fig 14. ( 1-10)
892/00283 Tool Kit Case Fig 14. ( 1-10)
892/00284 Digital Tachometer Fig 14. ( 1-10)
892/00285 Hyd. Oil Temperature Probe Fig 14. ( 1-10)
892/00286 Surface Temperature Probe Fig 14. ( 1-10)
892/00298 Fluke Meter Fig 14. ( 1-10)
892/01066 Interrogation Lead Fig 16. ( 1-10)
892/01174 Data Link Adaptor Fig 17. ( 1-11)
993/85700 Battery Tester Fig 15. ( 1-10)

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 Section 1 - General Information
Service Tools
Tool Detail Reference Section C - Electrics

Tool Detail Reference Section C - Electrics

Fig 15. 993/85700

Fig 14.
1 892/00283 Tool Kit Case
2 892/00298 Fluke Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Venture Microtach Digital Tachometer
5 892/00282 100 amp Shunt - open type
Fig 16. 892/01066
6 892/00285 Hydraulic Temperature Probe

1 - 10 9803/4160-12 1 - 10
 Section 1 - General Information
Service Tools
Tool Detail Reference Section C - Electrics

 

Fig 17. 892/01174

C031270

Fig 18. 718/20237

1 - 11 9803/4160-12 1 - 11
 Section 1 - General Information
Service Tools
Numerical List Section E - Hydraulics

Numerical List Section E - Hydraulics

The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is
testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any
are available from JCB Service. well equipped workshop or be available locally from any
good tool supplier.

Part Description Tool Detail

Number Reference
1406/0011 Bonded Washer Fig 21. ( 1-15)
1406/0014 Bonded Washer Fig 21. ( 1-15)
1406/0018 Bonded Washer Fig 21. ( 1-15)
1406/0021 Bonded Washer Fig 21. ( 1-15)
1406/0029 Bonded Washer Fig 21. ( 1-15)
1604/0006 Adapter Fig 22. ( 1-15)
1612/0006 Adapter Fig 22. ( 1-15)
816/00189 Blanking Cap Fig 24. ( 1-16)
816/00190 Blanking Cap Fig 24. ( 1-16)
816/00193 Blanking Cap Fig 24. ( 1-16)
816/00196 Blanking Cap Fig 24. ( 1-16)
816/00197 Blanking Cap Fig 24. ( 1-16)
816/00294 Blanking Cap Fig 24. ( 1-16)
816/15118 Pressure Test Adapter Fig 25. ( 1-16)
816/20008 Adapter Fig 22. ( 1-15)
816/55038 Pressure Test Adapter Fig 20. ( 1-15)
816/55040 Pressure Test Adapter Fig 20. ( 1-15)
892/00039 Spool Clamp Fig 28. ( 1-17)
892/00055 Blanking Plug Fig 23. ( 1-16)
892/00056 Blanking Plug Fig 23. ( 1-16)
892/00057 Blanking Plug Fig 23. ( 1-16)
892/00058 Blanking Plug Fig 23. ( 1-16)
892/00059 Blanking Plug Fig 23. ( 1-16)
892/00060 Blanking Plug Fig 23. ( 1-16)
892/00074 Female Connector Fig 26. ( 1-16)
892/00075 Female Connector Fig 26. ( 1-16)
892/00076 Female Connector Fig 26. ( 1-16)
892/00077 Female Connector Fig 26. ( 1-16)
892/00137 Micro-Bore Hose Fig 29. ( 1-17)
892/00223 Hand Pump Fig 29. ( 1-17)
892/00239 Charging Tool Fig 30. ( 1-17)

1 - 12 9803/4160-12 1 - 12
 Section 1 - General Information
Service Tools
Numerical List Section E - Hydraulics

Part Description Tool Detail

Number Reference
892/00253 Pressure Test Kit Fig 19. ( 1-15)
892/00255 Pressure Test Adaptor Fig 25. ( 1-16)
892/00256 Pressure Test Adaptor Fig 25. ( 1-16)
892/00257 Pressure Test Adaptor Fig 25. ( 1-16)
892/00258 Pressure Test Adaptor Fig 25. ( 1-16)
892/00259 Pressure Test Adaptor Fig 25. ( 1-16)
892/00260 Pressure Test Adaptor Fig 25. ( 1-16)
892/00261 Pressure Test Adaptor Fig 25. ( 1-16)
892/00262 Pressure Test Adaptor Fig 29. ( 1-17)
892/00263 Pressure Test Adaptor Fig 20. ( 1-15)
892/00264 Pressure Test Adaptor Fig 20. ( 1-15)
892/00265 Pressure Test Adaptor Fig 20. ( 1-15)
892/00268 Flow Monitoring Unit Fig 22. ( 1-15)
892/00269 Sensor Head Fig 22. ( 1-15)
892/00270 Load Valve Fig 22. ( 1-15)
892/00274 Adapter Fig 29. ( 1-17)
892/00275 Adapter Fig 22. ( 1-15)
892/00279 Gauge Fig 29. ( 1-17)
892/00309 A.R.V. Pressure Test Kit Fig 31. ( 1-17)
892/00335 A.R.V. Cartridge Removal Tool Fig 31. ( 1-17)
892/00340 Test Block Body Fig 31. ( 1-17)
892/00341 Setting Body Fig 31. ( 1-17)
892/00343 Spanner Fig 31. ( 1-17)
892/00345 Anti-cavitation Lock Out Bung Fig 31. ( 1-17)
892/00706 Test Probe Fig 29. ( 1-17)
892/00948 Charging Tool Fig 30. ( 1-17)
892/01042 Charging Tool Fig 30. ( 1-17)
892/01043 Adapter Fig 30. ( 1-17)
992/09300 Spanner Fig 27. ( 1-16)
992/09400 Spanner Fig 27. ( 1-16)
992/09500 Spanner Fig 27. ( 1-16)
992/09600 Spanner Fig 27. ( 1-16)
992/09700 Spanner Fig 27. ( 1-16)
992/10000 Spanner Fig 27. ( 1-16)
992/10100 Spool Clamp Fig 28. ( 1-17)
993/68300 Adjusting Pin Fig 31. ( 1-17)

1 - 13 9803/4160-12 1 - 13
 Section 1 - General Information
Service Tools
Numerical List Section E - Hydraulics
The following parts are replacement items for kits and Replacement items for kit no. 892/00253
would normally be included in the kit numbers above.

Part Description Tool Detail

Number Reference
892/00201 Replacement Gauge Fig 19. ( 1-15)
892/00202 Replacement Gauge Fig 19. ( 1-15)
892/00203 Replacement Gauge Fig 19. ( 1-15)
892/00254 Replacement Hose Fig 19. ( 1-15)

1 - 14 9803/4160-12 1 - 14
 Section 1 - General Information
Service Tools
Tool Detail Reference Section E- Hydraulics

Tool Detail Reference Section E- Hydraulics

892/00263 5/8 in BSP x 5/8 in F BSP x Test Point

892/00264 3/4 in BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point

Fig 21. Bonded Washers

1406/0011 1/4 in BSP
1406/0018 1/2 in BSP
1406/0014 5/8 in BSP
1406/0021 3/4 in BSP
Fig 19. Hydraulic Circuit Pressure test Kit 1406/0029 1.1/4 in BSP
892/00253 Pressure Test Kit
892/00201 Replacement gauge 0-20 bar (0-300 lbf/in2)
892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2)
892/00203 Replacement gauge 0-400 bar (0-6000 lbf/
in2)
892/00254 Replacement Hose

Fig 22. Flow Test Equipment

892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 to 100 l/min. (0 to 22 UK
gal/min)
892/00270 Load Valve
1406/0021Bonded Washer

Fig 20. Pressure Test `T' Adapters 1604/0006 Adapter 3/4 in M x 3/4 M BSP

892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 1612/0006 Adapter 3/4 in F x 3/4 M BSP
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 816/20008 Adapter 3/4 in F x 1/2 M BSP
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 892/00275 Adapter 1/2 in F x 3/4 M BSP

1 - 15 9803/4160-12 1 - 15
 Section 1 - General Information
Service Tools
Tool Detail Reference Section E- Hydraulics

892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point
Fig 23. Female Cone Blanking Cap
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00057 1/2 in BSP
892/00058 5/8 in BSP
892/00059 3/4 in BSP
892/00060 1 in BSP

Fig 26. Female Connectors

892/00074 3/8 in BSP x 3/8 in BSP
892/00075 1/2 in BSP x 1/2 in BSP
892/00076 5/8 in BSP x 5/8 in BSP
892/00077 3/4 in BSP x 3/4 in BSP

Fig 24. Male Cone Blanking Cap

816/00294 1/4 in BSP
816/00189 3/8 in BSP
816/00190 1/2 in BSP
816/00197 5/8 in BSP
816/00196 3/4 in BSP
816/00193 1 in BSP

Fig 27. Hexagon Spanners for Ram Pistons and End

Caps
992/09300 55 mm
992/09400 65 mm
992/09500 75 mm
992/09600 85 mm
992/09700 95 mm
992/10000 125 mm
Fig 25. Pressure Test Adapters

1 - 16 9803/4160-12 1 - 16
 Section 1 - General Information
Service Tools
Tool Detail Reference Section E- Hydraulics

Fig 28. Spool Clamps Fig 30. Accumulator Charge Equipment

892/00039 Spool Clamp 892/00239 Charging Tool (Diaphragm Accumulators)
992/10100 Spool Clamp 892/01042 Charging Tool (Diaphragm Accumulators)
892/01043 Adaptor (use with 892/01042)
892/00948 Charging Tool (Piston Accumulators)

Fig 29. Hand Pump Equipment

892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in. M BSP x 3/8 in. M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
Fig 31. Components for Valve Block A.R.V. Testing
892/00309 A.R.V. Pressure Test Kit
1 892/00340 Test Block Body
2 892/00341 Setting Body
3 993/68300 Adjusting Pin
4 892/00343 Spanner
5 892/00345 Anti-cavitation Lock Out Bung
6 892/00335 A.R.V. Cartridge Removal Tool

1 - 17 9803/4160-12 1 - 17
 Section 1 - General Information
Service Tools
Numerical List Section F - Transmission

Numerical List Section F - Transmission

The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is
removal and replacement of Transmission parts. These expected that such general tools will be available in any
tools are available from JCB Service. well equipped workshop or be available locally from any
good tool supplier.

Part Description Tool Detail

Number Reference
892/00817 Heavy Duty Socket Fig 33. ( 1-19)
892/00818 Heavy Duty Socket Fig 33. ( 1-19)
892/00819 Heavy Duty Socket Fig 33. ( 1-19)
892/00859 Spanner Stake Nut Fig 36. ( 1-20)
892/00860 Bearing Shim Remover Fig 39. ( 1-20)
892/00861 Bearing Remover Base Tool Fig 39. ( 1-20)
892/00862 Tab Washer Fitting Tool Fig 36. ( 1-20)
892/00863 Blanking Plate Fitting Tool Fig 40. ( 1-20)
892/00865 Computer Test Harness Fig 35. ( 1-19)
892/00866 Computer Test Indicator Box Fig 35. ( 1-19)
892/00867 Computer Test Interrogator Box Fig 35. ( 1-19)
892/01000 Bearing Puller Fig 41. ( 1-20)
892/01001 Bearing Tool Fig 42. ( 1-21)
892/01002 Spring Compressor Fig 43. ( 1-21)
892/01003 Bearing Puller Fig 41. ( 1-20)
892/01004 Bearing Tool Fig 42. ( 1-21)
892/01005 Bearing Tool Fig 42. ( 1-21)
892/01006 110 Volt Heater Fig 44. ( 1-21)
892/01007 Pipe Swaging Tool Fig 45. ( 1-21)
892/01008 Pipe Swaging Tool Fig 45. ( 1-21)
892/01009 Pipe Swaging Tool Fig 45. ( 1-21)
892/01010 Pipe Swaging Tool Fig 45. ( 1-21)
892/01013 Lifting Eye Fig 46. ( 1-21)
892/01014 Retainer Fig 47. ( 1-21)
892/01015 Lifting Eye Fig 46. ( 1-21)
892/00909 Puller Fig 38. ( 1-20)
992/04000 Torque Multiplier Fig 34. ( 1-19)
992/07603 Replacer - Bearing Cup Fig 32. ( 1-19)

1 - 18 9803/4160-12 1 - 18
 Section 1 - General Information
Service Tools
Tool Detail Reference Section F - Transmission

Tool Detail Reference Section F - Transmission

Fig 32. 992/07603

Fig 35.

Fig 33. Heavy Duty Socket for Durlock Bolts

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

Fig 34. 992/04000

Note: Use in conjunction with a torque wrench to give a
5:1 multiplication when tightening pinion nuts etc.
892/00865 Computer test harness
892/00866 Computer test indicator box
892/00867 Computer test interrogator box

1 - 19 9803/4160-12 1 - 19
 Section 1 - General Information
Service Tools
Tool Detail Reference Section F - Transmission

Fig 36. 892/00859

Fig 39.
1 892/00860 Bearing Remover Shim
2 892/00861 Bearing Remover Base Tool

Fig 37. 892/00862

Fig 40. 892/00863

Fig 41.

Fig 38. 892/00909

1 - 20 9803/4160-12 1 - 20
 Section 1 - General Information
Service Tools
Tool Detail Reference Section F - Transmission

Fig 45.
892/01007 Pipe Swaging Tool
Fig 42. 892/01008 Pipe Swaging Tool
892/01001 Bearing Tool 892/01009 Pipe Swaging Tool
892/01004 Bearing Tool 892/01010 Pipe Swaging Tool
892/01005 Bearing Tool

Fig 43. 892/01002 Fig 46.

892/01013 Lifting Eye
892/01015 Lifting Eye

Fig 44. 892/01006

Fig 47. 892/01014

1 - 21 9803/4160-12 1 - 21
 Section 1 - General Information
Service Tools
Numerical List Section K - Engine

Numerical List Section K - Engine

The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is
refurbishment of Engine parts. These tools are available expected that such general tools will be available in any
from JCB Service. well equipped workshop or be available locally from any
good tool supplier.

Part Description Tool Detail

Number Reference
892/00041 De-glazing Tool Fig 48. ( 1-23)

1 - 22 9803/4160-12 1 - 22
 Section 1 - General Information
Service Tools
Tool Detail Reference Section K - Engine

Tool Detail Reference Section K - Engine

Fig 48. 892/00041

Note: De-glazing Tool for Cylinder Bores (to assist
bedding-in of new piston rings)

For details of other engine service tools refer to Perkins

Service Manual Publication No. 9806/0100

1 - 23 9803/4160-12 1 - 23
 Section 1 - General Information
Service Consumables
Sealing and Retaining Compounds

Service Consumables
Sealing and Retaining Compounds
T11-001_3

Table 1.
Type Description Part No. Quantity
JCB Multi-Gasket A medium strength sealant suitable for all sizes of 4102/1212 50 ml
gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.
JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml
components. Gasketing for all sizes of flange where
the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be 4101/0651 50 ml
dismantled.
JCB Threadlocker and Sealer A medium strength locking fluid for sealing and 4101/0250 10 ml
retaining nuts, bolts, and screws up to 50 mm 4101/0251 50 ml
diameter, and for hydraulic fittings up to 25 mm
diameter.
JCB Threadlocker and Sealer A high strength locking fluid for sealing and retaining 4101/0550 10 ml
(High Strength) nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 200 ml
for hydraulic fittings up to 25 mm diameter.
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of 4104/0251 200 ml (Aerosol)
anaerobic products. 4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of 4104/1557 400 ml (Aerosol)
anaerobic adhesives and sealants.
Direct Glazing Kit For one pane of glass; comprises of: 993/55700

– 1 x Ultra Fast Adhesive (310 ml)

– 1 x Active Wipe 205 (30 ml)
– 1 x Black Primer 206J (30 ml)
– plus applicator nozzle etc.
Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml
Active Wipe 205 For direct glazing. 4104/1203 250 ml
Black Primer 206J For direct glazing. 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml

1 - 24 9803/4160-12 1 - 24
Section 2

Care and Safety

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-12



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section 2 - Care and Safety

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2-0 9803/4160-12 2-0

 Section 2 - Care and Safety

Contents Page No.

Safety Notices
Introduction .............................................................................................. 2 - 1
Safety Check List ..................................................................................... 2 - 2
Safety - Yours and Others .................................................................. 2 - 2
General Safety ................................................................................... 2 - 3
Operating Safety ................................................................................ 2 - 5
Maintenance Safety ............................................................................ 2 - 8
Safety Decals ................................................................................... 2 - 13

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

Contents Page No.

2 - ii 2 - ii
 Section 2 - Care and Safety

Safety Notices
Important Information
T1-015

The Operator Manual Safety Warnings

!MWARNING This safety alert system identifies

important safety messages in this
Study the Operator Manual before starting the manual. When you see this symbol, be
machine. You must understand and follow the alert, your safety is involved, carefuly
instructions in the Operator Manual. You must read the message that follows, and inform
observe all relevant laws and regulations. If you are other operators.
unsure about anything, ask your JCB dealer or
employer. Do not guess, you or others could be killed
In this publication and on the machine, there are safety
or seriously injured.
notices. Each notice starts with a signal word. The signal
INT-1-1-1_2
word meanings are given below.
Do not operate the machine without an Operator Manual.
!MDANGER
Treat the Operator Manual as part of the machine. Keep it
clean and in good condition. Replace the Operator Manual Denotes an extreme hazard exists. If proper
immediately if it is lost, damaged or becomes unreadable. precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1

!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2

!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3

2-1 9803/4160-12 2-1

 Section 2 - Care and Safety
Safety Notices
Safety Check List

Safety Check List

Safety - Yours and Others General Safety

INT-1-3-1_3 T1-007_2

All machinery can be hazardous. When a machine is

correctly operated and properly maintained, it is a safe
!MWARNING
machine to work with. But when it is carelessly operated or Operator Manual
poorly maintained it can become a danger to you (the You and others can be injured if you operate or
operator) and others. maintain the machine without first studying the
Operator Manual. Read the safety instructions before
In this manual and on the machine you will find warning operating the machine. If you do not understand
messages. Read and understand them. They tell you of anything, ask your employer or JCB dealer to explain
potential hazards and how to avoid them. If you do not fully it. Keep the Operator Manual clean and in good
understand the warning messages, ask your employer or condition. Do not operate the machine without an
JCB distributor to explain them. Operator Manual in the cab, or if there is anything on
the machine you do not understand.
But safety is not just a matter of responding to the INT-1-3-2_2
warnings. All the time you are working on or with the
machine you must be thinking what hazards there might be
and how to avoid them. !MWARNING
Care and Alertness
Do not work with the machine until you are sure that you All the time you are working with or on the machine,
can control it. take care and stay alert. Always be careful. Always be
alert for hazards.
Do not start any job until you are sure that you and those INT-1-3-5
around you will be safe.

If you are unsure of anything, about the machine or the job, !MWARNING
ask someone who knows. Do not assume anything. Clothing
You can be injured if you do not wear the proper
Remember clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
BE CAREFUL Examples of protective clothing are: a hard hat, safety
BE ALERT shoes, safety glasses, a well fitting overall, ear-
BE SAFE protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained.
INT-1-3-6

!MWARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be aware
of medicines which can cause drowsiness.
INT-1-3-9_2

2-2 9803/4160-12 2-2

 Section 2 - Care and Safety
Safety Notices
Safety Check List

!MWARNING !MDANGER
Feeling Unwell Lightning
Do not attempt to operate the machine if you are Lightning can kill you. Do not use the machine if there
feeling unwell. By doing so you could be a danger to is lightning in your area.
yourself and those you work with. 5-1-1-2
8-1-2-4

!MWARNING
!MWARNING Machine Modifications
Mobile Phones This machine is manufactured in compliance with
Switch off your mobile phone before entering an area legislative and other requirements. It should not be
with a potentially explosive atmosphere. Sparks in altered in any way which could affect or invalidate any
such an area could cause an explosion or fire of these requirements. For advice consult your JCB
resulting in death or serious injury. Distributor.
INT-1-3-10_2
Switch off and do not use your mobile phone when
refuelling the machine.
INT-3-3-9

!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

!MWARNING
Raised Equipment
Raised equipment can fall and injure you. Do not walk
or work under raised equipment unless safely
supported.
13-1-1-6

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

2-3 9803/4160-12 2-3

 Section 2 - Care and Safety
Safety Notices
Safety Check List

Operating Safety !MWARNING

You could be killed or seriously injured if you operate
!MWARNING a machine with a damaged or missing ROPS/FOPS. If
Machine Condition the Roll Over Protection Structure (ROPS)/Falling
A defective machine can injure you or others. Do not Objects Protection Structure (FOPS) has been in an
operate a machine which is defective or has missing accident, do not use the machine until the structure
parts. Make sure the maintenance procedures in this has been renewed. Modifications and repairs that are
manual are completed before using the machine. not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-2_2
INT-2-1-9_6

!MWARNING !MWARNING
Machine Limits
Operating the machine beyond its design limits can Work Sites
damage the machine, it can also be dangerous. Do not Work sites can be hazardous. Inspect the site before
operate the machine outside its limits. Do not try to working on it. Look for potholes, weak ground, hidden
upgrade the machine performance with unapproved rocks etc. Check for utilities such as electric cables
modifications. (overhead and underground), gas and water pipes etc.
INT-2-1-4
Mark the positions of the underground cables and
pipes. Make sure that you have enough clearance
beneath overhead cables and structures.
!MWARNING INT-2-2-1
Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
!MWARNING
the fault has been corrected. Communications
Bad communications can cause accidents. Keep
INT-2-1-5
people around you informed of what you will be doing.
If you will be working with other people, make sure any
!MWARNING hand signals that may be used are understood by
The engine has exposed rotating parts. Switch OFF the everybody. Work sites can be noisy, do not rely on
engine before working in the engine compartment. Do spoken commands.
not use the machine with the engine cover open. INT-2-2-3

5-2-6-5
!MWARNING
!MWARNING Parking
Exhaust Gases An incorrectly parked machine can move without an
Breathing the machine exhaust gases can harm and operator. Follow the instructions in the Operator
possibly kill you. Do not operate the machine in closed Manual to park the machine correctly.
spaces without making sure there is good ventilation. INT-2-2-4_2
If possible, fit an exhaust extension. If you begin to
feel drowsy, stop the machine at once and get into
fresh air.
!MWARNING
Banks and Trenches
INT-2-1-10_2
Banked material and trenches can collapse. Do not
work or drive too close to banks and trenches where
there is danger of collapse.
INT-2-2-5

2-4 9803/4160-12 2-4

 Section 2 - Care and Safety
Safety Notices
Safety Check List

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

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

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

Hazardous Atmospheres
This machine is designed for use in normal out door
!MWARNING
atmospheric conditions. It should not be used in an Keep the machine controls clean and dry. Your hands
enclosed area without adequate ventilation. Do not and feet could slide off slippery controls. If that
use the machine in a potentially explosive happens you could lose control of the machine.
atmosphere, i.e. combustible vapours, gas or dust, 2-2-3-6
without first consulting your JCB Distributor.
INT-2-1-14
!MWARNING
!MCAUTION Visibility
Accidents can be caused by working in poor visibility.
Regulations Use your lights to improve visibility. Keep the road
Obey all laws, work site and local regulations which lights, windows and mirrors clean.
affect you and your machine.
INT-1-3-3 Do not operate the machine if you cannot see clearly.
5-1-4-7

2-5 9803/4160-12 2-5

 Section 2 - Care and Safety
Safety Notices
Safety Check List

!MWARNING !MWARNING
Electrical Power Cables Entering/Leaving
You could be electrocuted or badly burned if you get Entering or leaving the cab or canopy must only be
the machine or its attachments too close to electrical made where steps and handrails are provided. Always
power cables. face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
You are strongly advised to make sure that the safety clean and dry. Do not jump from the machine. Do not
arrangements on site comply with the local laws and use the machine controls as handholds, use the
regulations concerning work near electric power lines. handrails.
INT-2-1-7_1
Before you start using the machine, check with your
electricity supplier if there are any buried power
cables on the site.
!MWARNING
Fires
There is a minimum clearance required for working If your machine is equipped with a fire extinguisher,
beneath overhead power cables. You must obtain make sure it is checked regularly. Keep it in the correct
details from your local electricity supplier. machine location until you need to use it.
2-2-5-4
Do not use water to put out a machine fire, you could
!MCAUTION spread an oil fire or get a shock from an electrical fire.
Use carbon dioxide, dry chemical or foam
If you have an attachment which is not covered in the extinguishers. Contact your nearest fire department as
Operator Manual do not install it, use it or remove it quickly as possible. Firefighters should use self-
until you have obtained, read and understood the contained breathing apparatus.
pertinent information. Install attachments only on the INT-3-2-7_2
machines for which they were designed.
5-5-1-1_2
!MWARNING
!MWARNING Engine Panels
The engine has exposed rotating parts.
Use only the JCB approved attachments that are
specified for your machine. Operating with non- Do not open the bonnet while the engine is running.
specified attachments can overload the machine, Keep other people clear while you raise the engine
causing possible damage and machine instability cover using the boom. Do not use the machine with
which could result in injury to yourself or others. the bonnet open or the cover raised.
5-1-2-1
The use of non-approved attachments could invalidate
your warranty.
2-4-5-2_1

!MWARNING
Controls
You or others can be killed or seriously injured if you
operate the control levers from outside the cab.
Operate the control levers only when you are correctly
seated inside the cab.
INT-2-1-3

2-6 9803/4160-12 2-6

 Section 2 - Care and Safety
Safety Notices
Safety Check List

Maintenance Safety !MWARNING

If you try to charge a frozen battery, or jump start and
!MWARNING run the engine, the battery could explode. Do not use
Communications a battery if its electrolyte is frozen. To prevent the
Bad communications can cause accidents. If two or battery electrolyte from freezing, keep the battery at
more people are working on the machine, make sure full charge.
each is aware of what the others are doing. Before 0125
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
!MWARNING
attachments and linkages, and anywhere beneath or Battery Gases
behind the machine. People can be killed or injured if Batteries give off explosive gases. Keep flames and
these precautions are not taken. sparks away from the battery. Do not smoke close to
INT-3-1-5
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
!MWARNING the terminals with metal; use a hydrometer or
Repairs voltmeter.
If your machine does not function correctly in any way, INT-3-1-8
get it repaired straight away. Neglect of necessary
repairs could result in an accident or affect your
health. Do not try to do repairs or any other type of
!MDANGER
maintenance work you do not understand. To avoid Electrolyte
injury and/or damage get the work done by a specialist Battery electrolyte is toxic and corrosive. Do not
engineer. breathe the gases given off by the battery. Keep the
GEN-1-5_2
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.

!MWARNING INT-3-2-1_3

Metal Splinters
You can be injured by flying metal splinters when
!MWARNING
driving metal pins in or out. Use a soft faced hammer Battery Terminals
or copper pin to remove and fit metal pins. Always The machine is negatively earthed. Always connect
wear safety glasses. the negative pole of the battery to earth.
INT-3-1-3_2
When connecting the battery, connect the earth (-) lead
last.
!MWARNING
Electrical Circuits When disconnecting the battery, disconnect the earth
Understand the electrical circuit before connecting or (-) lead first.
disconnecting an electrical component. A wrong INT-3-1-9
connection can cause injury and/or damage.
INT-3-1-4 !MWARNING
Fluid Under Pressure
!MCAUTION Fine jets of fluid at high pressure can penetrate the
Do not disconnect the battery while the engine is skin. Keep face and hands well clear of fluid under
running, otherwise the electrical circuits may be pressure and wear protective glasses. Hold a piece of
damaged. cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
INT-3-1-14
skin, get medical help immediately.
INT-3-1-10_2

2-7 9803/4160-12 2-7

 Section 2 - Care and Safety
Safety Notices
Safety Check List

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

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

2-8 9803/4160-12 2-8

 Section 2 - Care and Safety
Safety Notices
Safety Check List

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

Hydraulic Hoses Used fluoroelastomeric components whose

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

Do not weld near the affected area during the drying 3 Contain all removed material, gloves etc. used in
period. Take the same precautions as for oil to keep this operation in sealed plastic bags and dispose
Waxoyl off your skin. Do not breathe the fumes. Apply of in accordance with Local Authority
in a well-ventilated area. Regulations.
5-3-1-9
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
!MWARNING INT-3-3-5_3

Working Under the Machine

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

2-9 9803/4160-12 2-9

 Section 2 - Care and Safety
Safety Notices
Safety Check List

!MWARNING !MWARNING
To avoid burning, wear protective gloves when Accumulators
handling hot components. To protect your eyes, wear The accumulators contain hydraulic fluid and gas at
goggles when using a wire brush to clean high pressure. Prior to any work being carried out on
components. systems incorporating accumulators, the system
HYD-1-3 pressure must be exhausted by a JCB distributor, as
the sudden release of the hydraulic fluid or gas may
!MWARNING cause injury.
INT-3-1-17
Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the alternator
!MWARNING
before arc-welding on the machine or attached Compressed air is dangerous. Wear suitable eye
implements. protection and gloves. Never point a compressed air
jet at yourself or others.
If the machine is equipped with sensitive electrical 0147_1
equipment, i.e. amplifier drivers, electronic control
units (E.C.U.s), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
!MWARNING
sensitive electrical equipment could result in An exploding tyre can kill. Inflated tyres can explode if
irreparable damage to these components. over-heated or over-inflated. Follow the instructions
given when inflating the tyres. Do not cut or weld the
Parts of the machine are made from cast iron; welds rims. Use a tyre/wheel specialist for all repair work.
on cast iron can weaken the structure and break. Do 2-3-2-7_2
not weld cast iron. Do not connect the welder cable or
apply any weld to any part of the engine.
!MWARNING
Always connect the welder earth (ground) cable to the Jacking
same component that is being welded, i.e. boom or A machine can roll off jacks and crush you unless the
dipper, to avoid damage to pivot pins, bearings and wheels have been blocked. Always block the wheels at
bushes. Attach the welder earth (ground) cable no the opposite end of the machine that is to be jacked.
more than 0.6 metres (2 feet) from the part being Do not work underneath a machine supported only by
welded. jacks. Always support a jacked-up machine on axle
INT-3-1-15_2 stands before working underneath it.
INT-3-2-8

!MWARNING
Counterweights
!MWARNING
Your machine may be fitted with counterweights. They Under no circumstances must the engine be run with
are extremely heavy. Do not attempt to remove them. the transmission in gear and only one driving wheel
INT-3-2-5 jacked clear of the ground, since the wheel on the
ground will move the machine.
!MWARNING INT-3-1-16

Turning the Engine

Do not try to turn the engine by pulling the fan or fan
!MWARNING
belt. This could cause injury or premature component Wheels and tyres are heavy. Take care when lifting or
failure. moving them.
0094
Store with care to ensure that they cannot fall and
cause injury.
13-3-1-7_1

2 - 10 9803/4160-12 2 - 10
 Section 2 - Care and Safety
Safety Notices
Safety Check List

!MWARNING
Asbestos
Asbestos dust can damage your lungs. Some engine
gaskets contain asbestos. Do not dismantle the
engine or exhaust system; get these jobs done by a
qualified person who has a copy of the engine service
manual.
5-1-6-1

2 - 11 9803/4160-12 2 - 11
 Section 2 - Care and Safety
Safety Notices
Safety Check List

Safety Decals
Decals on the machine warn you of particular hazards.
Each decal is attached close to a part of the machine
where there is a possible hazard. Read and make sure you
understand the safety message before you work with or on
that part of the machine.

Keep all decals clean and readable. Replace lost or

damaged decals. The decals and their attachment points
are as illustrated. Each decal has a part number printed on
it, use this number to order a new decal from you JCB
dealer.

!MWARNING
Decals
Decals on the machine warn you of particular hazards.
You can be injured if you do not obey the decal safety
instructions.

Each decal is attached close to a part of the machine

where there is a possible hazard. Make sure
replacement parts include warning decals where
necessary.

Keep all decals clean and readable. Replace lost or

damaged decals. Each decal has a part number
printed on it, use this number to order a new decal
from your JCB distributor.
INT-3-3-3_1

!MWARNING
If you need eye-glasses for reading, make sure you
wear them when reading the safety decals. Decals are
strategically placed around the machine to remind you
of possible hazards. Do not over-stretch or place
yourself in dangerous positions to read the decals.
INT-3-3-4_1

2 - 12 9803/4160-12 2 - 12
 Section 2 - Care and Safety
Safety Notices
Safety Check List











Fig 1.

2 - 13 9803/4160-12 2 - 13
Section 3

Routine Maintenance
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-15



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

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

Notes:

1-2 9803/4160-15 1-2

 Section 3 - Routine Maintenance

Contents Page No.

Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No.
1410000)
Health and Safety ...................................................................................... 3-1
Service Schedules ..................................................................................... 3-5
Service Schedules 426 from M1231500, 436 from M1305000 ............... 3-10
Lubricants and Capacities ....................................................................... 3-14
Lubricants and Capacities - North American Capacities and Lubricant Equiva-
lent ........................................................................................................... 3-15
Lubricants and Capacities - 436 From 533692 ........................................ 3-17
Lubricants and Capacities - 426 From 532500 ........................................ 3-19
Lubricants and Capacities - 436 From Serial No. 534200 ....................... 3-20
Lubricants and Capacities - 426 from M1231500 .................................... 3-21
Lubricants and Capacities - 436 from M1305000 .................................... 3-22
Seat Belt .................................................................................................. 3-23
Articulation Lock ...................................................................................... 3-24
Articulation Lock - 426 from M1231500, 436 from M1305000 ................. 3-26
Loader Arm Safety Strut .......................................................................... 3-27
Engine Covers ......................................................................................... 3-28
Rear Grille 426 from M1231500, 436 from M1305000 ............................ 3-29
Heater Door - 426 from M1231500, 436 from M1305000 ....................... 3-30
Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500 ....... 3-31
Greasing 426 from M1231500, 436 from M13050000 ............................. 3-36
Automatic Greasing System .................................................................... 3-39
Electrical System ..................................................................................... 3-42
Engine ..................................................................................................... 3-45
Cooling System ....................................................................................... 3-61
Fan Belts ................................................................................................. 3-72
Fuel System ............................................................................................. 3-79
Hydraulic System ..................................................................................... 3-97
Transmission ......................................................................................... 3-101
Front and Rear Axles ............................................................................. 3-106
Cab Heater Filters ................................................................................. 3-109
Windscreen Washer .............................................................................. 3-114

Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No.
1410000)
Service Requirements ........................................................................... 3-117
Service Schedules ................................................................................. 3-118
Lubricants and Capacities ..................................................................... 3-124
Cleaning the Machine ............................................................................ 3-126
Checking for Damage ............................................................................ 3-127
Checking the ROPS/FOPS Structure .................................................... 3-128
Articulation Lock .................................................................................... 3-129
Loader Arm Safety strut ......................................................................... 3-130
Greasing ................................................................................................ 3-131
Automatic Greasing System .................................................................. 3-134
Access Panels ....................................................................................... 3-137
Heating and Ventilation ......................................................................... 3-139
Electrical System ................................................................................... 3-141
Engine ................................................................................................... 3-146
Fuel System ........................................................................................... 3-152
Hydraulic System ................................................................................... 3-156
Transmission ......................................................................................... 3-158
Wheels and Tyres .................................................................................. 3-161
Window Washers ................................................................................... 3-162

3-i 3-i
 Section 3 - Routine Maintenance

Contents Page No.

3-ii 3-ii
 Section 3 - Routing Maintenance

Routine Maintenance (426 up to Ser. No. 1295000,

436 up to Ser. No. 1410000)
Health and Safety
T3-001_3

Lubricants Waste Disposal

Introduction !MCAUTION
It is most important that you read and understand this It is illegal to pollute drains, sewers or the ground.
information and the publications referred to. Make sure all Clean up all spilt fluids and/or lubricants.
your colleagues who are concerned with lubricants read it
too. Used fluids and/or lubricants, filters and contaminated
materials must be disposed of in accordance with
Hygiene local regulations. Use authorised waste disposal sites.
INT-3-2-14
JCB lubricants are not a health risk when used properly for
their intended purposes. All waste products should be disposed of in accordance
with all the relevant regulations.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and The collection and disposal of used oil should be in
irritation. accordance with any local regulations. Never pour used
engine oil into sewers, drains or on the ground.
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with Handling
fuel contamination.
New Oil
Whenever you are handling oil products you should
maintain good standards of care and personal and plant There are no special precautions needed for the handling
hygiene. For details of these precautions we advise you to or use of new oil, beside the normal care and hygiene
read the relevant publications issued by your local health practices.
authority, plus the following.
Used Oil
Storage
Used engine crankcase lubricants contain harmful
Always keep lubricants out of the reach of children. contaminants.

Never store lubricants in open or unlabelled containers. 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. Note the following when removing engine oil
from skin:

a Wash your skin thoroughly with soap and water.

3-1 9803/4160-14 3-1

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Health and Safety
b Using a nail brush will help.

c Use special hand cleansers to help clean dirty

hands.

d Never use petrol, diesel fuel, or paraffin for

washing.

3 Avoid skin contact with oil soaked clothing.

4 Don't keep oily rags in pockets.

5 Wash dirty clothing before re-use.

6 Throw away oil-soaked shoes.

First Aid - Oil

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

!MWARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.

Extinguish oil and lubricant fires with carbon dioxide,

dry chemical or foam. Fire fighters should use self
contained breathing apparatus.
7-3-1-3_1

3-2 9803/4160-14 3-2

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Health and Safety

Battery Warning Symbols

The following warning symbols may be found on the

!MWARNING battery.
Batteries give off an explosive gas. Do not smoke
when handling or working on the battery. Keep the Symbol Meaning
battery away from sparks and flames.
Keep away from children.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
metallic items (watches, rings, zips etc) away from the
battery terminals. Such items could short the Shield eyes.
terminals and burn you.

Set all switches in the cab to OFF before

disconnecting and connecting the battery. When
disconnecting the battery, take off the earth (-) lead
first. No smoking, no naked flames, no sparks.

Re-charge the battery away from the machine, 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 five
Explosive Gas.
minutes before connecting it up.

When reconnecting, fit the positive (+) lead first.

First Aid - Electrolyte

Battery acid.
Do the following if electrolyte:

GETS INTO YOUR EYES

Note operating instructions.
Immediately flush with water for 15 minutes, always get
medical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.
!MCAUTION
Do not disconnect the battery while the engine is
GETS ONTO YOUR SKIN running, otherwise the electrical circuits may be
damaged.
Flush with water, remove affected clothing. Cover burns INT-3-1-14
with a sterile dressing then get medical help.

5-3-4-3_1

3-3 9803/4160-14 3-3

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Health and Safety

!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4

!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3

!MCAUTION
Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
receptacle and must be disposed of in accordance
with local environmental waste regulations.
INT-3-1-12

!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8

3-4 9803/4160-14 3-4

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules

Service Schedules

A Badly Maintained Machine Is A Danger To The Operator Apart From The Daily Jobs, The Schedules Are Based On
And The People Working Around Him. Make Sure That Machine Running Hours. Keep A Regular Check On The
The Regular Maintenance And Lubrication Jobs Listed In Hourmeter Readings To Correctly Gauge Service
The Service Schedules Are Done To Keep The Machine In Intervals. Do Not Use A Machine Which Is Due For A
A Safe And Efficient Working Condition. Service. Make Sure Any Defects Found During The
Regular Maintenance Checks Are Rectified Immediately.
!MWARNING
Calendar equivalents:
Maintenance
Maintenance must be done by suitably qualified Every 10 Hours = Daily
personnel. Before attempting any maintenance work, Every 50 Hours = Weekly
make sure the machine is safe. Park on level ground.
Every 500 Hours = Six Months
If it is necessary to work with the loader arms raised,
then the loader arm safety strut must be fitted as Every 1000 Hours = Yearly
shown in Loader Arm Safety Strut in MAINTENANCE Every 2000 Hours = 2 Years
section.
Every 6000 Hours = 6 Years
2-3-1-1

Pre-start Cold Checks, Service Points and Operation 10 100 250 As 500 1000 2000
Fluid Levels Hr(1) Hr(2) Hr and Hr Hr Hr
When
ENGINE
Oil Level (426, 436) - Check

Oil Level (446) - Check

Oil and Filter - Change

Oil and Filter (Tier 2 Engines) (3) - Change

Air Cleaner Outer Element - Change

Air Cleaner Inner Element - Change

Fuel Filter - Drain

Fuel Filter - Change

Coolant Level - Check

Coolant Filter (446) - Change

Coolant - Test

Antifreeze Strength - Check

Coolant - Change

Fuel Sedimenter - Drain

Fan Belt Tension/Condition - Check

Valve Clearances (426B/436B Engine YB Build) - Check and Adjust

3-5 9803/4160-14 3-5

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules

Pre-start Cold Checks, Service Points and Operation 10 100 250 As 500 1000 2000
Fluid Levels Hr(1) Hr(2) Hr and Hr Hr Hr
When
Valve Clearances (426B YH Build/436B YK - Check and Adjust
Build)
Engine Mount Security - Check

Air Compressor Belt Tension/Condition (if fitted) - Check

TRANSMISSION AND AXLES

Transmission Oil Level - Check

Transmission Oil - Change

Transmission Strainer/Filter - Change

Axle(s) Oil Level - Check

Axle(s) Oil - Change

Hub Oil Levels - Check

Hub Oil - Change

Prop. Shaft and Universal joints - Grease

Prop. Shaft Security - Check

Centre Prop. Shaft Slide - Grease

Axle Breather(s) - Clean

Tyre Pressures and Condition - Check

Wheel Nut Security - Check

Axle Mount Security - Check

Transmission Mount Security - Check

Parking Brake Operation - Check and Adjust

Rear Axle Pivot - Grease

Bevel Ring Gear Deflection Plunger - Check and Adjust

HYDRAULICS
Oil Level - Check

Oil Filter - Change

Oil - Sample

Oil - Change

Suction Strainer - Clean

Servo Filter - Change

Tank Filler Cap - Change

3-6 9803/4160-14 3-6

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules

Pre-start Cold Checks, Service Points and Operation 10 100 250 As 500 1000 2000
Fluid Levels Hr(1) Hr(2) Hr and Hr Hr Hr
When
Hoses & Pipework - Damage or Leaks - Check

ELECTRICS
Instrument Panel Operation - Check

Wiring for Chaffing - Check

Battery Terminals for Condition and Tightness - Check

Battery Charge Condition - Check

BODY AND FRAMEWORK

Loader End Pivots - Grease

All Hinges - Grease

Lower Centre Pivot - Grease

Steer Ram Pivots - Grease

Upper Centre Pivot - Grease

Machine Condition Generally - Check

CAB
Windscreen Washer Fluid Level - Fill

Cab Heater Intake Filter - Clean

Cab Recirculation Filter - Clean

ROPS/FOPS Structures - Check

Seat Belt Security and Condition - Check

(1) Operations must be carried out at the end of each set period, ie. The 10 Hour operations must be carried out after every
10 hours.
(2) 100 Hour operations marked with a symbol are carried out at the Initial 100 Hour Service ONLY.
(3) Tier 2 Engines 426 from Serial Number 532500 (BTAA 5.9-C / SO18487), Tier 2 Engines 436 from Serial Number
534200 (BTAA 5.9-C / SO18521)

Functional Test and and Final Inspection Operation 10 100 250 As 500 1000 2000
Hr(1) Hr(2) Hr and Hr Hr Hr
When
ENGINE
Idle Speed - Check and Adjust

Torque Converter Stall Speed - Check

Combined Stall Speed - Check

Max. No Load Speed - Check and Adjust

3-7 9803/4160-14 3-7

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules

Functional Test and and Final Inspection Operation 10 100 250 As 500 1000 2000
Hr(1) Hr(2) Hr and Hr Hr Hr
When
Throttle System and Control Cable - Check

Operation of Stop Control/E.S.O.S. - Check

Exhaust Smoke - Check

Fuel System For Leaks and Contamination - Check

Exhaust System Security - Check

Air Inlet System Security - Check

Coolant System for Leaks - Check

TRANSMISSION AND AXLES

Clutch Pack Pressures - Check

Clutch Disconnect/Dump Button - Check

Clutch Pack Calibration - Check

Speed Change and Selection - Check

Forward/Reverse Selection/Operation - Check

Neutral Start Operation - Check

Reverse Alarm (if fitted) - Check

Oil Cooler and Pipework - Check

HYDRAULICS
MRV Pressure - Check and Adjust

Steer Circuit MRV Pressure - Check and Adjust

ARV Pressure - Check and Adjust

Operation of All Services - Check

Hoses for Damage and Leaks - Check

Pipework for Damage and Leaks - Check

Piston Rods and Gland Seals - Check

ELECTRICS
Starter Motor - Check

Alternator - Check

Gauges and Warning Lights - Check

Proximity Sensor Function - Check

Cab Switches - Check

Wiper Motors - Check

3-8 9803/4160-14 3-8

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules

Functional Test and and Final Inspection Operation 10 100 250 As 500 1000 2000
Hr(1) Hr(2) Hr and Hr Hr Hr
When
Heater - Check

Other (give details) - Check

CAB
Glazing for Correct Fit - Check

Doors and Hinges - Check

Tool Kit and Handbook - Check

Locks and Keys - Check

Seat/Seat Belts - Check

PAINTWORK
Condition - Check
ATTACHMENTS
Attachment Circuit Pressures - Check

Operation - Check

REGISTRATION/CERTIFICATION
Form 2530 (F91) (UK Requirement) - Lift - Check

Form 2531 (F96/F97) (UK Requirement) - Check

SWL Stickers (UK) - Renew as

Required

(1) Operations must be carried out at the end of each set period, ie. The 10 Hour operations must be carried out after every
10 hours.
(2) 100 Hour operations marked with a symbol are carried out at the Initial 100 Hour Service ONLY.

Table 1. Key
Regular Maintenance Check

Initial 100 Hour Check Only

3-9 9803/4160-14 3-9

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules 426 from M1231500, 436 from M1305000

Service Schedules 426 from M1231500, 436 from M1305000

A poorly maintained machine is a hazard. Doing the

regular maintenance and lubrication jobs listed in these
schedules will help keep the machine in safe running
order.

!MWARNING
Maintenance must be done only by suitably qualified
and competent persons.

Before doing any maintenance make sure the machine

is safe, it should be correctly parked on level ground.

To prevent anyone starting the engine, remove the

starter key. Disconnect the battery when you are not
using electrical power. If you do not take these
precautions you could be killed or injured.
8-3-1-1

A Service History Record Book is supplied with every

machine to enable you to plan your service
requirements and keep a service history record. This
record book should be dated, signed and stamped by
your Distributor at machine installation and each time
your machine is serviced.
2-3-1-9

Apart from the daily jobs, the schedules are based on

machine running hours. Keep a regular check on the hour
meter reading. Do not use a machine which is due for a
regular service. Rectify any defects found during regular
maintenance before clearing the machine for use.

Calendar equivalents:
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 100 Hours = Monthly
Every 500 Hours = Six Months
Every 1000 Hours = 1 Year
Every 2000 Hours = 2 Years

3-10 9803/4160-14 3-10

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules 426 from M1231500, 436 from M1305000

Owner or Operator Tasks First 100 hrs only (to be completed by JCB Distributor) Regular Service

Table 2. Engine
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 500 Hr 1000 Hr 2000 Hr
Hr
Oil Level and Condition Check

Oil and Filter Change (1)

Coolant Change

Coolant Level Check

Coolant strength and Condition Check

Air Cleaner Dust Valve Clean(2)

Air Cleaner Outer Element Change (3)
Air Cleaner Inner Element Change

Fuel System For Leaks and Check

Contamination
Fuel Filter Drain

Fuel Filter Change

Fuel Sedimenter Check

Fan Belt Tension/Condition Check

Fan Belt Change

Valve Clearances Check/Adjust

External Oil Leaks Check

(1) In arduous conditions change the oil and filter after every 250 Hours or three months (whichever comes first).
(2) Clean more often when working in dusty environments
(3) Change outer element more frequently in dusty operating environments.

Table 3. Transmission and Axles

Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Transmission Oil Level Check

Transmission Oil Change

Transmission Strainer/Filter Change

Differential Oil Level Check

Differential Oil Change

Hub Oil Check

3-11 9803/4160-14 3-11

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules 426 from M1231500, 436 from M1305000

Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Hub Oil Change

Axle Breathers Clean

Tyre Pressures/Condition Check

Wheel Nut Security Check

Axle Mount Security Check

Axle Mount Security Check

Propshaft Security Check

Bevel Ring Gear Deflection Check

Plunger
Propshaft and Universal Joints Grease

Table 4. Hydraulics
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Oil Level Check

Oil Filter Change

Oil Change
and
Sample
Servo Filter Change

Tank Filler Cap Change

Tank Suction Strainers (2 off) Clean

Hoses, Rams and Pipework for Check

Damage or Leaks

3-12 9803/4160-14 3-12

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Service Schedules 426 from M1231500, 436 from M1305000
Table 5. Brakes
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Parkbrake Operation Check

Table 6. Electrics
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Instrument Panel Operation Check

Battery Electrolyte Level (if applicable) Check

Battery Charge and Condition Check

Battery Terminals for Condition & Check

Tightness
Wiring for Chaffing and Routing Check

Table 7. Bodywork and Cab

Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Machine Condition Generally Check

Wing Mirrors Condition & Security Check

All Pivot Pins Grease

Propshaft Joints Grease(1)

Windscreen Washer Fluid Level Fill

Cab Heater Intake Filter(s) Clean(2)

Seat Belt Condition and Security Check

Hinges Grease

ROPS/FOPS Structure Check

(1) Grease more frequently when operating in arduous conditions.

(2) Clean more frequently in dusty operating environments.

3-13 9803/4160-14 3-13

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities

Lubricants and Capacities

Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine is gently run-in. Under no circumstances should the whenever a new or reconditioned engine is fitted to the
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.

Table 8.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil 426, 436
-18 to 0° C 16 litres (3.5 UK gal) JCB Torque Converter Fluid
-10 to 50° C 446
18.9 litres (4.2 UK gal) JCB 15W/40 Multigrade API CE, MIL-L-
2104C/D
Gearbox
426 (1)
24 litres (5.3 UK gal) JCB Torque Converter Fluid API CE, MIL-L-
2104C/D
436 (1) 23 litres (5.1 UK gal)
Front Axle 40.0 litres (8.8 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105A
Rear Axle 38.0 litres (8.5 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105A
Hydraulic System
426 200 litres (44.0 UK gal) JCB HP32 Hydraulic Fluid ISO VG32
436 210 litres (46.2 UK gal)
Fuel System
426 212 litres (46.6 UK gal) Diesel Oil (see Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
436, 446 230 litres (50.6 UK gal)
Cooling System
426, 436 50 litres (11.0 UK gal) Water/Anti-freeze (see Coolant ASTM D3306-74
Mixtures ( 3-62))
446 38 litres (8.4 UK gal)
Grease Points JCB HP Grease Lithium based

(1) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.

Note: The total hydraulic system capacity depends on the and watch the level indicator.
equipment being used. Fill the system with all rams closed

3-14 9803/4160-14 3-14

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - North American Capacities and Lubricant Equivalent

Lubricants and Capacities - North American Capacities and Lubricant

Equivalent

Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine is gently run-in. Under no circumstances should the whenever a new or reconditioned engine is fitted to the
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.

Table 9.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil 426 To Ser. No. 531347
-18 to 0° C 16 liters (4.2 US gal) JCB 10W or JCB 15W/40 MIL-L-2104E
-10 to 50° C 436 To Ser. No. 533408 JCB 30W API CD/CE
16 liters (4.2 US gal)
446
18.9 liters (5.0 US gal)

Engine Oil 426 From Ser. No.

531348
-20 to +10°C (-4 to 16 liters (4.2 US gal) JCB 10W CF-4/SG, SAE
+50°F) 10W
436 From Ser. No.
533409
-10 to +50°C (14 to 16 liters (4.2 US gal) JCB 15W40 CF-4/SG, SAE
122°F) 15W40
Gearbox
426 (1) 24 liters (6.3 US gal) JCB 10W or JCB 15W/40 MIL-L-2104E
436 (1)
23 liters (6.1 US gal)
Front Axle 40.0 liters (10.6 US gal) JCB LS Gear Oil MIL-L-2105A
Rear Axle 38.0 liters (10.0 US gal) JCB LS Gear Oil MIL-L-2105A
Hydraulic System
426 200 liters (52.8 US gal) (2)
JCB Hydraulic Fluid ISO VG46
436 (3) 210 liters (55.5 US gal)
Fuel System
426 212 liters (56.0 US gal) Diesel Oil (see Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
436, 446 230 litres (60.8 US gal)
Cooling System

3-15 9803/4160-14 3-15

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - North American Capacities and Lubricant Equivalent

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

SPECIFICATION
426, 436 50 litres (13.2 US gal) Water/Anti-freeze (see Coolant ASTM D3306-74
Mixtures ( 3-62))
446 38 litres (10.0 US gal)
Grease Points JCB MOLY EP # Grease Lithium based, No.
2

(1) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
(2) Above 32°F (0°C). In conditions below 32°F (0°C) use JCB HP32 Hydraulic Fluid (ISO VG32).
(3) Also 426 machines (USA ONLY) built after November 1998.

Note: The total hydraulic system capacity depends on the

equipment being used. Fill the system with all rams closed
and watch the level indicator.

3-16 9803/4160-14 3-16

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - 436 From 533692

Lubricants and Capacities - 436 From 533692

Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine is gently run-in. Under no circumstances should the whenever a new or reconditioned engine is fitted to the
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.

Table 10.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil(1)
16 litres (3.5 UK gal) JCB Extreme Performance Engine Oil ACEA E3/B3/A3
-10°C to +50°C (14°F to 122°F) API CH-4/A3
Gearbox(2)
426 24 litres (5.3 UK gal) JCB HP Universal ATF ZF TE-MIL 06, 11,
12, 14
436 34 litres (7.5 UK gal) JCB HP Universal ATF ZF TE-MIL 06, 11,
12, 14
Axles 26.0 litres (5.7 UK gal) JCB Gear Oil LS API GL4, MIL-L-
2105B(3)
426 (Front)
436 39.0 litres (8.6 UK gal) JCB Gear Oil LS API GL4, MIL-L-
2105B(3)
(Rear)
37.0 litres (8.1 UK gal) JCB Gear Oil LS API GL4, MIL-L-
2105B(3)
Hydraulic System
426 200 litres (44.0 UK gal) JCB Special Hydraulic Fluid ISO VG32
436 210 litres (46.2 UK gal) JCB Special Hydraulic Fluid ISO VG32
Cooling System
50 litres (11.0 UK gal) Four Seasons Anti-freeze and Summer ASTM D3306,
Coolant/Water (see Coolant BS6580
Mixtures ( 3-62))
Fuel System
426 212 litres (46.6 UK gal) Diesel Oil (see Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
436 230 litres (50.6 UK gal) Diesel Oil (see Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
Grease Points JCB HP Grease Lithium based

3-17 9803/4160-14 3-17

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - 436 From 533692

(1) If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed at 250 hours.
(2) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
(3) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Note: The total hydraulic system capacity depends on the

equipment being used. Fill the system with all rams closed
and watch the level indicator.

Note: If JCB Special MPL Grease is used, all 100 hour

greasing operations must be carried out at TEN (10)
HOUR intervals.

Note: Biodegradable Hydraulic Fluid is a factory option

ONLY. Replenish with JCB Biodegradable Multigrade
Hydraulic Fluid. For further information, contact
Earthmovers Technical Service.

3-18 9803/4160-14 3-18

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - 426 From 532500

Lubricants and Capacities - 426 From 532500

Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine is gently run-in. Under no circumstances should the whenever a new or reconditioned engine is fitted to the
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.

Table 11.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil
(Tier 2) 14 litres (3.1 UK gal) JCB Extreme Performance ACEA E3/B3/A3
Engine Oil 15W/40 API CH-4/A3
CAUTION: DO NOT USE ORDINARY ENGINE OIL FOR TIER 2 ENGINES
Gearbox
426 30 litres (6.6 UK gal) JCB HP Universal ATF ZF TE-MIL 06, 11,
12, 14
Front Axle 26.0 litres (5.7 UK gal) JCB Special Gear Oil LS API GL4, MIL-
2105B
Rear Axle 26.0 litres (5.7 UK gal) JCB Special Gear Oil LS API GL4, MIL-
2105B
Hydraulic System
426 210 litres (46.2 UK gal) JCB Special Hydraulic Fluid ISO VG46
Multigrade
Fuel System
426 230 litres (50.6 UK gal) Diesel Oil (see Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
Cooling System
426, 35 litres (7.7 UK gal) Water/Anti-freeze (see Coolant ASTM D3306-74
Mixtures ( 3-62))
Grease Points JCB HP Grease Lithium based

Note: The total hydraulic system capacity depends on the

equipment being used. Fill the system with all rams closed
and watch the level indicator.

3-19 9803/4160-14 3-19

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - 436 From Serial No. 534200

Lubricants and Capacities - 436 From Serial No. 534200

Note: New engines DO NOT require a running-in period. should be drained after the first 100 hours operation and
The engine/machine should be used in a normal work the engine filled with the appropriate recommended grade
cycle immediately; glazing of the piston cylinder bores, as shown in the lubrication chart. JCB 10W/30 Multigrade
resulting in excessive oil consumption, could occur if the should also be used for the first 100 hours operation
engine is gently run-in. Under no circumstances should the whenever a new or reconditioned engine is fitted to the
engine be allowed to idle for extended periods; (e.g. machine. After the first 100 hours operation, it is essential
warming up without load). Engines of new machines are that the 10W/30 oil is replaced by the lubricant
filled at the factory with JCB 10W/30 Multigrade oil. This oil recommended below.

Table 12.
ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil
(Tier 2) 14 litres (3.1 UK gal) JCB Extreme Performance ACEA E3/B3/A3
Engine Oil 15W/40 API CH-4/A3
CAUTION: DO NOT USE ORDINARY ENGINE OIL FOR TIER 2 ENGINES
Gearbox
436 30 litres (6.6 UK gal) JCB HP Universal ATF ZF TE-MIL 06, 11,
12, 14
Front Axle 26.0 litres (5.7 UK gal) JCB Special Gear Oil LS API GL4, MIL-
2105B
Rear Axle 26.0 litres (5.7 UK gal) JCB Special Gear Oil LS API GL4, MIL-
2105B
Hydraulic System
436 210 litres (46.2 UK gal) JCB Hydraulic Fluid ISO VG46
Multigrade
Fuel System
436 230 litres (50.6 UK gal) Diesel Oil (see Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
Cooling System
436 35 litres (7.7 UK gal) Water/Anti-freeze (see Coolant ASTM D3306-74
Mixtures ( 3-62))
Grease Points JCB HP Grease Lithium based

Note: The total hydraulic system capacity depends on the

equipment being used. Fill the system with all rams closed
and watch the level indicator.

3-20 9803/4160-14 3-20

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - 426 from M1231500

Lubricants and Capacities - 426 from M1231500

Note: New engines DO NOT require a running-in period. engine is gently run-in. Under no circumstances should the
The engine/machine should be used in a normal work engine be allowed to idle for extended periods; (e.g.
cycle immediately; glazing of the piston cylinder bores, warming up without load).
resulting in excessive oil consumption, could occur if the

Table 13. 426 and 436 Machines

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil
-10 to 50° C (1) 14 litres (3.1 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
API CH-4A3
Gearbox 30 litres (6.6 UK gal)(2) JCB HP Universal ATF ZF TE-ML 06, 11,
12, 14
Axles 26 litres (5.7 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105B(3)
Hydraulic System 210 litres (46.2 UK gal)(4) JCB HP Hydraulic Fluid ISO VG46
Cooling System 35 litres (7.7 UK gal) Water/Anti-freeze ( Coolant ASTM D3306-74
Mixtures ( 3-62))
Fuel System 230 litres (50.6 UK gal) Diesel Oil ( Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
Grease Points JCB HP Grease(5) Lithium based
Autolube System (if JCB MPL EP Grease Lithium based
fitted)

(1) If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.
(2) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
(3) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
(4) The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and
watch the level indicator.
(5) If JCB Special MPL Grease is used for normal greasing, all 100 hour greasing operations must be carried out at TEN
(10) HOUR intervals.

Note: Biodegradeable Hydraulic Fluid is a factory option

ONLY. Replenish with JCB Biodegradeable Multigrade
Hydraulic fluid. For further information, contact Wheeled
Loader Technical Service.

3-21 9803/4160-14 3-21

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Lubricants and Capacities - 436 from M1305000

Lubricants and Capacities - 436 from M1305000

Note: New engines DO NOT require a running-in period. engine is gently run-in. Under no circumstances should the
The engine/machine should be used in a normal work engine be allowed to idle for extended periods; (e.g.
cycle immediately; glazing of the piston cylinder bores, warming up without load).
resulting in excessive oil consumption, could occur if the

Table 14. 426 and 436 Machines

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil
-10 to 50° C (1) 14 litres (3.1 UK gal) JCB Extreme Performance Engine Oil 15W/40 ACEA E3/B3/A3
API CH-4A3
Gearbox 30 litres (6.6 UK gal)(2) JCB HP Universal ATF ZF TE-ML 06, 11,
12, 14
Axles 26 litres (5.7 UK gal) JCB LS Gear Oil API GL4, MIL-L-
2105B(3)
Hydraulic System 210 litres (46.2 UK gal)(4) JCB HP Hydraulic Fluid ISO VG46
Cooling System 35 litres (7.7 UK gal) Water/Anti-freeze ( Coolant ASTM D3306-74
Mixtures ( 3-62))
Fuel System 230 litres (50.6 UK gal) Diesel Oil ( Types of Fuel ( 3-79)) ASTM D975-66T
Nos. 1D, 2D.
Grease Points JCB HP Grease(5) Lithium based
Autolube System (if JCB MPL EP Grease Lithium based
fitted)

(1) If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.
(2) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
(3) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
(4) The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and
watch the level indicator.
(5) If JCB Special MPL Grease is used for normal greasing, all 100 hour greasing operations must be carried out at TEN
(10) HOUR intervals.

Note: Biodegradeable Hydraulic Fluid is a factory option

ONLY. Replenish with JCB Biodegradeable Multigrade
Hydraulic fluid. For further information, contact Wheeled
Loader Technical Service.

3-22 9803/4160-14 3-22

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Seat Belt

Seat Belt

Checking the Seat Belt Condition and

Security
T3-008

!MWARNING
When a seat belt is fitted to 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. Fit a new seat
belt every three years.
2-3-1-7_1

Inspect the seat belt for signs of fraying and stretching.

Check that the stitching is not loose or damaged. Check
that the buckle assembly is undamaged and works
correctly.

Check that the belt mounting bolts are undamaged,

correctly fitted and tightened.

3-23 9803/4160-14 3-23

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Articulation Lock

Articulation Lock

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

If the articulation lock is not fitted you could be

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

Installing the Articulation Lock

On the Wheeled Loader, the articulation safety lock is
stowed on the machine as shown. The articulation lock is
fitted with the machine in a 'straight ahead' position.

1 Steer the machine to bring the front and rear wheels

in a straight line.

2 Apply the parking brake, put the transmission in

neutral.

3 Remove pin 1-A2 and pivot articulation lock into

locking position, replace pin 1-A2 at position 1-A1. If
pin will not fit, turn steering wheel slightly to align hole.

4 Stop the engine.

3-24 9803/4160-14 3-24

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Articulation Lock

Removing the Articulation Lock 1 Remove pin at postion 1-A1.

2 Return the articulation lock to its stowage position as

!MWARNING shown.
Always make sure the articulation safety lock has
been removed before attempting to drive the machine. 3 Lock the articulation lock into its stowage position by
The machine cannot be steered with the articulation replacing pin at position 1-A2 as shown.
lock fitted.
16-3-1-4

Fig 1.

3-25 9803/4160-14 3-25

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Articulation Lock - 426 from M1231500, 436 from M1305000

Articulation Lock - 426 from M1231500, 436 from M1305000

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

If the articulation lock is not fitted you could be

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

Installing the Articulation Lock

The articulation lock is stowed in the machine's tool box.
The articulation lock is fitted, as illustrated, with the
machine in the `straight ahead' position.

1 Steer the machine to bring the front and rear wheel in

a straight line.

2 Apply the park brake, put the transmission in neutral

and stop the engine.

3 Remove the articulation lock bar C from the tool box.

4 Position the articulation lock bar. Fit pins A and B into

the articulation lock positions as shown. If the pins do
not fit, fit pin A, then turn the steering wheel slightly to Fig 2.
align the hole for pin B.
Removing the Articulation Lock

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

1 Remove locking pins A and B.

2 Stow locking bar C in the machine's tool box.

3-26 9803/4160-14 3-26

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Loader Arm Safety Strut

Loader Arm Safety Strut

Installing the Safety Strut Removing the Safety Strut

!MWARNING !MWARNING
Raised Equipment You could be killed or injured if the loader control is
Never walk or work under raised equipment unless it accidentally operated. Make sure no-one comes near
is supported by a mechanical device. Equipment the machine while you remove the safety strut.
which is supported only by a hydraulic device can 2-3-1-3
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped). 1 Make sure the parking brake is on, and that the
13-2-3-7_2 transmission is in neutral.

!MWARNING 2 Raise the loader arm to take the weight off the safety
strut 3A. Stop the engine.
You could be killed or seriously injured if the loader
control is accidentally operated. Make sure that no- 3 Remove the strut:
one goes near the machine whilst you fit the safety
strut. a Release securing strap 3B.
16-3-1-5
b Remove safety strut.
1 Empty the bucket and raise the loader arm enough to
fit the safety strut 3A. c Return the safety strut to its stowage position.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Fit the strut:

a Remove the strut from its stowage position.

b Place the strut around the ram.

c Secure the strut into position using strap 3B.

4 Start the engine.

5 Slowly lower the loader arm onto the safety strut.

Stop the movement immediately the weight of the arm
is supported by the strut.

Note: Extreme care must be taken when lowering the Fig 3.

loader arm onto the safety strut. 'Feather' the lever to lower
the loader arm slowly.

3-27 9803/4160-14 3-27

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine Covers

Engine Covers

Opening the Engine Covers - 426 from

M1231500, 436 from M1305000

!MWARNING
The engine has exposed rotating parts. Switch OFF the
engine before working in the engine compartment. Do
not use the machine with the engine cover open.
5-2-6-5

Opening the Engine Covers

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

2 Pull handle 4D. It is recommended that the panels are

kept locked.

3 Pull handle 4E out and up, allow the gas-strut to open

the panel.

Closing the Engine Covers

1 Pull handle 4E down and inwards.

2 Make sure the panel is latched.

Fig 4.

3-28 9803/4160-14 3-28

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Rear Grille 426 from M1231500, 436 from M1305000

Rear Grille 426 from M1231500, 436 from M1305000

Opening the Rear Grille

1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Open the left side engine cover Engine

Covers ( 3-28) and unlatch the rear grille by pulling
the release catch A.

3 Open the rear grille by pulling the bottom of the grille

out and up, the grille will be lifted by the gas struts.

Closing the Rear Grille

1 Close the rear grille by pulling the bottom of the grille
down against the pressure of the gas struts. Keep a
firm hold on the grille.

2 Make sure the rear grille is latched. Close and lock

the engine cover.

Fig 5.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Heater Door - 426 from M1231500, 436 from M1305000

Heater Door - 426 from M1231500, 436 from M1305000

Opening the Heater Door

1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Unlock and press catch A.

Closing the Heater Door

1 Close the heater door by pushing on the area
surrounding the catch.

2 Make sure the heater door is latched. It is

recommended that the door is kept locked.

Fig 6.

3-30 9803/4160-14 3-30

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500

Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500

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

4-Ram Loader Arm Pivot Points

Total of 20 grease points (7-5 to 7-24)

Shovel Pivot Pins

Total of 4 grease points. (7-1 to 7-4)

For interval see Service Schedules ( 3-5)

The machine must be greased regularly to keep it working

efficiently. Regular greasing will also increase the
machine's working life.

Grease should be applied with a grease gun, normally two

strokes of the gun should be sufficient. Stop the greasing
procedure when fresh grease appears at the joint. Use the
recommended grease. See Lubricants and
Capacities ( 3-14).

In the following illustrations, the grease points are

numbered. Count off the grease points as you apply
grease to each one. Refit the dust caps after greasing.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500

Fig 7.

3-32 9803/4160-14 3-32

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500

Z-Bar Loader Arm Pivot Points Shovel Pivot Pins

Total of 11 grease points (8-4 to 8-13) Total of 3 grease points (8-1 to 8-3)

For interval see Service Schedules ( 3-5)

Fig 8.

3-33 9803/4160-14 3-33

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500

Centre Pivot and Steering Ram

Total of 7 grease points

For interval see Service Schedules ( 3-5)

Fig 9.

3-34 9803/4160-14 3-34

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing - 426 up to Ser. No. 1231500, 436 up to Ser. No. 130500

Propshafts !MWARNING
Total of 7 grease points Make the machine safe before working underneath it.
Park the machine on level ground and lower the
Note: Centre Propshaft Sliding Spline - grease point 10-1. attachments, (If it is necessary to work with the loader
arms raised, then the loader arm safety strut must be
For interval see Service Schedules ( 3-5) fitted). See Loader Arm Safety Strut in MAINTENANCE
section. Engage the park brake, put the transmission
in neutral and stop the engine. Block both sides of all
four wheels. If you are working near the articulation
danger zone, fit the articulation safety lock. See
Articulation Lock in MAINTENANCE section.
4-3-2-4_1

Fig 10.

3-35 9803/4160-14 3-35

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing 426 from M1231500, 436 from M13050000

Greasing 426 from M1231500, 436 from M13050000

!MWARNING Shovel Pivot Pins (HT)

Make the machine safe before working underneath it. Total of 6 grease points. (1 to 6)
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put Loader Arm Pivot Points (HT)
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
Total of 18 grease points (7 to 24)
Disconnect the battery, to prevent the engine being
started while you are beneath the machine.
GEN-4-1_1
       

For interval Service Schedules 426 from M1231500, 
436 from M1305000 ( 3-10) 

The machine must be greased regularly to keep it working
 
efficiently. Regular greasing will also increase the  
machine's working life.  
  
Grease should be applied with a grease gun, normally two  
strokes of the gun should be sufficient. Stop the greasing 
procedure when fresh grease appears at the joint. Use the 
recommended grease, Lubricants and Capacities -
426 from M1231500 ( 3-21). Fig 11.

In the following illustrations, the grease points are Shovel Pivot Pins (ZX)
numbered. Count off the grease points as you apply
grease to each one. Refit the dust caps after greasing. Total of 4 grease points. (1 to 4)

Note: In arduous conditions the shovel pivot pins should Loader Arm Pivot Points (ZX)
be greased at least every ten (10) hours.
Total of 8 grease points (5 to 13)

 
 



 
 


Fig 12.

3-36 9803/4160-14 3-36

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing 426 from M1231500, 436 from M13050000

Centre Pivot Steer Rams

Total of 3 grease points Total of 4 grease points (6 to 9)

Fig 14.
Fig 13.

Rear Axle Pivots

Total of 2 grease points (4 and 5)

3-37 9803/4160-14 3-37

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Greasing 426 from M1231500, 436 from M13050000

Propshafts !MWARNING
Total of 7 grease points Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

    

 

Fig 15.

Cab Door Hinges

When greasing the cab door hinges, open the door and
stand as shown.

Fig 16.

3-38 9803/4160-14 3-38

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Automatic Greasing System

Automatic Greasing System

When the ignition is ON, the greasing system performs all

operations automatically.

Grease Points
 

The following points are greased by the automatic system

(when fitted):

1 Shovel Pivot Pins

2 Loader Arm Pivot Points

3 Centre Pivot and Steering Rams

Note: All other grease points must continue to be greased

as per the Service Schedules

Filling the Reservoir

It is essential that the correct grease is used in this system.

1 Remove the dust cap from the filler coupling A. 

2 Carefully clean the area around the filler coupling and

the coupling on the filler hose.

3 Attach the filler hose to the coupling A.

Fig 17.
4 Fill the reservoir C until the top of the follower plate D
(the plate on top of the grease) is level with the
maximum level mark.

5 Remove the filler hose, clean the coupling and refit

the dust cap.

Note: Any air introduced during filling will exit via the
reservoir vent. If large amounts of air are present, carry out
a continuous greasing cycle for one minute.

3-39 9803/4160-14 3-39

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Automatic Greasing System

Testing the System Replacing the Fill Point Filter

In order to test the correct operation of the system, carry 1 Clean the area around the filler coupling A.
out a single greasing cycle.
2 Remove the filler coupling A from the filter F.
Single Greasing Cycle
3 Loosen locknut E.
1 Turn starter switch to IGN.
4 Remove filter F.
2 Press test button B for 3 to 5 seconds.
Note: Grease may flow from the housing G when the filter
3 The system will perform a single cycle test. is removed.

In order to prime the system after cleaning the machine or

to vent the system; a continuous should be carried out.

Continouous Greasing Cycle

1 Turn starter switch to IGN.

2 Press test button B for more than 6 seconds.

3 The system will perform a continuous cycle run.

Note: The continuous greasing cycle will continue to run

until the starter switch is turned to OFF.

Fig 18.

!MCAUTION
Pressurised grease may flow from the filter housing as
the filter is loosened.
4-3-5-6

5 Screw the new filter into the filter housing, hand-tight

only, until the O ring contacts the filter housing G.

6 Tighten locknut E to 15Nm (133lbf in).

7 Refit the filler coupling.

3-40 9803/4160-14 3-40

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Automatic Greasing System

System Display Unit

Item Indication Description

A Yellow Lamp Low Level Reservoir requires replenishing.
B Red Lamp Error System not operating due to insufficient grease.
C Green Lamp Light Duty Long interval between grease cycles.
Greasing Mode
D Green Lamp Normal Duty Standard interval between grease cycles.
Greasing Mode
E Green Lamp Heavy Duty Short interval between grease cycles.
Greasing Cycle
F Greasing Mode Selection Switch - Press the mode switch repeatedly until the
desired mode lamp (C, D or E) illuminates.









Fig 19.

3-41 9803/4160-14 3-41

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Electrical System

Electrical System

Battery
Note: Before commencing work on the battery you must
read Section c - Electrics - Service Procedures.

Checking the Electrolyte Level

Maintenance free batteries used in normal temperate

climate applications should not need topping up. However,
in certain conditions (such as prolonged operation at
tropical temperatures or if the alternator overcharges) the
electrolyte level should be checked as described below.

!MCAUTION
Do not disconnect the alternator, the battery, or any
part of the charging circuit with the engine running. Fig 20.
8-3-4-1

!MWARNING
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.
5-2-2-4

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.

2 Remove the battery cell covers and check the

electrolyte level in each cell. The electrolyte should
be 6 mm (0.25 in) above the plates.

!MWARNING
Do not top the battery up with acid. The electrolyte
could boil out and burn you.
2-3-4-6

3 Top-up if necessary with distilled water or de-ionised

water.

4 Check the Connections. Make sure that the terminals

are tight and clean. Coat them with petroleum jelly to
prevent corrosion.

3-42 9803/4160-14 3-42

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Electrical System

Jump Starting The Engine 1 The parking brake should have been engaged when
the machine was last parked. If it is not engaged,
engage it now.
!MWARNING
Do not use a battery if its electrolyte is frozen. To 2 Set all switches in the cab to off.
prevent the battery electrolyte from freezing, keep the
battery fully charged. 3 Lower the shovel to the ground, if it is not already
there. It will lower itself under its own weight when you
Do not try to charge a frozen battery or jump-start and operate the lever. Operate the lever carefully to
run the engine, the battery could explode. control the rate of descent. If your machine is fitted
with hose burst protection valves you will not be able
Batteries produce a flammable gas, which is to lower the shovel. In this case install the safety strut.
explosive; do not smoke when checking the
electrolyte levels. 4 Connect the positive booster cable to the positive (+)
terminal on the machine battery. Connect the other
When jump-starting from another vehicle, make sure end of this cable to the positive (+) terminal of the
that the two vehicles do not touch each other. This booster supply.
prevents any chance of sparks near the battery.
5 Connect the negative (-) booster cable to a suitable
Set all the machine switches to their OFF positions point on the engine.
before connecting the external power supply. Even
with the starter switch set to off some circuits will be 6 Start the engine.
energised when the external power supply is
connected. 7 Disconnect the negative booster cable from the
engine. Then disconnect it from the booster supply.
Do not connect the booster (slave) supply directly
across the starter motor. Doing this by-passes the 8 Disconnect the positive booster cable from the
neutral gear safety switch. If the machine is in gear, it positive (+) terminal on the battery. Then disconnect
may 'runaway' and kill or injure bystanders. it from the booster supply.

Use only sound jump leads with securely attached

connectors. Connect one jump lead at a time.

The machine has a negative earth electrical system.

Check which battery terminal is positive (+) before
making any connections.

Keep metal watch straps and jewellery away from the

jump lead connectors and the battery terminals - an
accidental short could cause serious burns and
damage equipment.

Make sure you know the voltage of the machine. The

booster (slave) supply must not be higher than that of
the machine. Using a higher voltage supply will
damage your machine's electrical system.

If you do not know the voltage of your booster (slave)

supply, then contact your JCB dealer for advice. Do
not attempt to jump-start the engine until you are sure
of the voltage of the booster (slave) supply.
4-2-2-3_1

3-43 9803/4160-14 3-43

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Electrical System

Fuses and Relays

For fuse, primary fuse and relay information please refer to
Section C - Electrics - Technical Data.

3-44 9803/4160-14 3-44

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Engine

Checking the Oil Level

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2

1 Park the machine on level ground and lower the

attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the right side engine cover.

4 Check that the oil level is between the two marks on

the dipstick A. Fig 22. 426, 436

5 If necessary, add the recommended oil through the

filler point B. See Lubricants and
Capacities ( 3-14).

6 Make sure the filler cap and the dipstick are secure.
Close and lock the engine cover.

Fig 21. 436 From Ser. No. 533692

Fig 23. 446

3-45 9803/4160-14 3-45

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Changing the Oil and Filter 4 Clean and refit the drain plug and its 'O' ring and
tighten the drain plug to 34 Nm (25 lbf ft). DO NOT
OVERTIGHTEN.
!MWARNING
Make the machine safe before working underneath it. 5 Unscrew the filter canisters 25C. Remember that they
Park the machine on level ground, lower the will be full of oil.
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block 6 Clean filter head 25D.
both sides of all four wheels.
7 Add clean engine oil to the new filter canisters. Allow
Disconnect the battery, to prevent the engine being time for the oil to pass through the filter elements.
started while you are beneath the machine.
8 Smear the seal 25E on the new filter canisters with
GEN-4-1_1
clean engine oil.

!MCAUTION 9 Screw in the new filter canisters - hand tight only.

Hot oil and engine components can burn you. Make
10 Fill the engine with the recommended oil, to the MAX
sure the engine is cool before doing this job.
mark on the dipstick, through the filler point. Wipe off
2-3-3-2
any spilt oil, refit the filler cap and make sure it is
1 Do Steps 1 to 3 of Checking the Oil secure. Close the engine cover.
Level ( 3-101).
11 Make sure the engine will not start and turn the
2 Place a suitable container beneath the drain plug 24A engine using the starter key until the oil pressure
(to catch the oil). warning light is extinguished.

3 Remove drain plug and its 'O' ring and drain the oil Note: To make sure the engine will not start, remove the
from the sump. Renew the 'O' ring. engine shut-off solenoid fuse. See Section C - Elecrtics.

12 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has
cooled, check the oil level.

Fig 24.

Note: Some machines are fitted with a self-sealing drain

plug. Use a self-sealing drain kit with this type.

3-46 9803/4160-14 3-46

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Fig 25.

3-47 9803/4160-14 3-47

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Changing the Oil and Filter (446)

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2

1 Park the machine on level ground and lower the

attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the left side engine cover.

4 Place a suitable container beneath the drain plug 26A

(to catch the oil).

5 Remove drain plug and its 'O' ring and drain the oil
from the sump. Renew the 'O' ring.
Fig 26.
6 Clean and refit the drain plug and its 'O' ring and
tighten the drain plug to 34 Nm (25 lbf ft). DO NOT 9 Add clean engine oil to the new filter canister. Allow
OVERTIGHTEN. time for the oil to pass through the filter element.

7 Clean the area around the filter head. Unscrew the 10 Smear the seal 28E on the new filter canister with
filter canister 28C. Remember that it will be full of oil. clean engine oil.

8 Clean filter head 28D. Make sure that the `O' ring is 11 Screw in the new filter canister until it just contacts the
removed. filter head.

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

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

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

3-48 9803/4160-14 3-48

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine
14 Make sure the engine will not start and turn the
engine using the starter key until the oil pressure
warning light is extinguished.

Note: To make sure the engine will not start, remove the
engine shut-off solenoid fuse (see Section C - Electrics).

15 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has
cooled, check the oil level.

Fig 27.

Fig 28.

3-49 9803/4160-14 3-49

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Checking the Oil Level (426 from S/N

532500 and 436 from S/N 534200)

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2

1 Park the machine on level ground and lower the

attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the right side engine cover.

4 Check that the oil level is between the two marks on

the dipstick 29A. Fig 30. 436

5 If necessary, add the recommended oil through the

filler point 29B. See Lubricants and
Capacities ( 3-14).

6 Make sure the filler cap and the dipstick are secure.
Close and lock the engine cover.

Fig 29. 426

3-50 9803/4160-14 3-50

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Changing the Oil and Filter (426 from S/N

532500 and 436 from S/N 534200)

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2

1 Park the machine on level ground and lower the

attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the left side engine cover.

4 Place a suitable container beneath the drain plug (to

catch the oil).

5 Remove the self sealing drain plug outer threaded

Fig 31.
cover 31A.
10 Add clean engine oil to the new filter canister. Allow
6 Fit the self sealing drain kit threaded union (with
time for the oil to pass through the filter element.
attached drain pipe) and drain the sump oil.
11 Smear the seal 33E on the new filter canister with
7 Remove the self seal drain kit, clean and refit the
clean engine oil.
outer cover. (Do not over tighten the cover.)
12 Screw in the new filter canister until it just contacts the
8 Clean the area around the filter head. Unscrew the
filter head.
filter canister 33C. Remember that it will be full of oil.
13 Turn the filter a further 3/4 of a turn.
9 Clean filter head 33D. Make sure that the `O' ring is
removed.
14 Fill the engine with the recommended oil, to the MAX
mark on the dipstick, through the filler point. Wipe off
any spilt oil, refit the filler cap and make sure it is
secure. Close the engine covers.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine
15 Make sure the engine will not start and turn the
engine using the starter key until the oil pressure
warning light is extinguished.

Note: To make sure the engine will not start, remove the
engine shut-off solenoid fuse (see Section C - Electrics).

16 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has
cooled, check the oil level.

Fig 32.

Fig 33.

3-52 9803/4160-14 3-52

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Checking the Oil Level - 426 from

M1231500, 436 from M1305000

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2

1 Park the machine on level ground and lower the

attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the right side engine cover.

4 Check that the oil level is between the two marks on

the dipstick 34A.

5 If necessary, add the recommended oil through the

filler point 34B, Lubricants and Capacities - 426
from M1231500 ( 3-21).

6 Make sure the filler cap and the dipstick are secure.
Close and lock the engine cover.

Fig 34.

3-53 9803/4160-14 3-53

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Changing the Oil and Filter - 426 from

M1231500, 436 from M1305000

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2

1 Park the machine on level ground and lower the

attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the left side engine cover.

4 Place a suitable container beneath the drain plug (to

catch the oil).

5 Remove the self sealing drain plug outer threaded

Fig 35.
cover 35A.
10 Add clean engine oil to the new filter canister. Allow
6 Fit the self sealing drain kit threaded union (with
time for the oil to pass through the filter element.
attached drain pipe) and drain the sump oil.
11 Smear the seal 37E on the new filter canister with
7 Remove the self seal drain kit, clean and refit the
clean engine oil.
outer cover. (Do not over tighten the cover.)
12 Screw in the new filter canister until it just contacts the
8 Clean the area around the filter head. Unscrew the
filter head.
filter canister 37C. Remember that it will be full of oil.
13 Turn the filter a further 3/4 of a turn.
9 Clean filter head 37D. Make sure that the `O' ring is
removed.
14 Fill the engine with the recommended oil, to the MAX
mark on the dipstick, through the filler point. Wipe off
any spilt oil, refit the filler cap and make sure it is
secure. Close the engine covers.

3-54 9803/4160-14 3-54

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine
15 Make sure the engine will not start and turn the
engine using the starter key until the oil pressure
warning light is extinguished.

Note: To make sure the engine will not start, remove the
engine shut-off solenoid fuse (see Section C - Electrics).

16 Refit the engine shut-off solenoid fuse and start the

engine. Check for leaks. When the engine has
cooled, check the oil level.

Fig 36.

Fig 37.

3-55 9803/4160-14 3-55

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Air Filter blocked switch connector is fitted. Check all hoses for
condition and tightness.
Changing the Elements

Note: In a dusty working environment, the outer element

may have to be renewed more frequently than the service
schedule recommendation. A new inner element must be
fitted at latest every third time the outer element is
changed. As a reminder, mark the inner element with a felt
tip pen each time you change only the outer element. DO
NOT attempt to wash or clean elements - they must be
renewed.

!MCAUTION
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates.
2-3-3-1

!MCAUTION
Do not run the engine when the outer element has
been removed.
16-3-3-1

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

2 Open the right side engine cover.

3 If changing the inner element, disconnect the filter

induction hose 38L to prevent dust getting into the
engine. Cover the hose to prevent rain and dirt getting
into the engine.

4 Unscrew knob 38A and remove cover 38B.

5 Unscrew nut 38C. Pull out the outer element 38D.

Take care not to tap or knock the element as you
remove it. If necessary, unscrew nut 38H and pull out
the inner element 38J.

6 Clean inside canister 38E and dust valve 38G.

7 Carefully insert the new elements into the canister.

Make sure they seat correctly, by smearing the seals
38K and 38F with grease and checking for a witness
mark on the canister base. Fit and tighten nuts 38H
and 38C.

8 Connect the induction hose. Make sure that the dust

valve 38G is at the bottom. Make sure the air filter

3-56 9803/4160-14 3-56

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Fig 38.

3-57 9803/4160-14 3-57

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine
Changing the Elements (436 from Ser. No 533692
to Ser. No. 534199)

Note: In a dusty working environment, the outer element

may have to be renewed more frequently than the service
schedule recommendation. A new inner element must be
fitted at latest every third time the outer element is
changed. As a reminder, mark the inner element with a felt
tip pen each time you change only the outer element. DO
NOT attempt to wash or clean elements - they must be
renewed.

!MCAUTION
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates.
2-3-3-1

!MCAUTION
Do not run the engine when the outer element has
been removed.
16-3-3-1

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

2 Open the right side engine cover.

3 If changing the inner element, disconnect the filter

induction hose 39H to prevent dust getting into the
engine. Cover the hose to prevent rain and dirt getting
into the engine.

4 Unfasten latches 39A and remove cover 39B. Pull out

the outer element 39C. Take care not to tap or knock
the element as you remove it. If necessary, lift tabs at
39D and pull out the inner element 39E.

5 Clean inside canister 39F and dust valve 39G.

6 Carefully insert the new elements into the canister.

Make sure that seals 39J and 39K seat correctly.

7 Refit cover 39B and fasten latches 39A. Make sure

that dust valve 39G is at the bottom.

8 Connect the induction hose 39H. Make sure the air

filter blocked switch connector is fitted. Check all
hoses for condition and tightness.

3-58 9803/4160-14 3-58

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Fig 39.

3-59 9803/4160-14 3-59

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Engine

Changing the Air Filter Elements (426 1 Apply the parking brake, put the transmission in
neutral and stop the engine.
from S/N 532500 and 436 from S/N
534200) 2 Open the right side engine cover.

Note: In a dusty working environment, the outer element 3 If changing the inner element, disconnect the filter
may have to be renewed more frequently than the service induction hose 40H to prevent dust getting into the
schedule recommendation. A new inner element must be engine. Cover the hose to prevent rain and dirt getting
fitted at latest every third time the outer element is into the engine.
changed. As a reminder, mark the inner element with a felt
tip pen each time you change only the outer element. DO 4 Release the end cover spring clips 40-1 and remove
NOT attempt to wash or clean elements - they must be end cover 40A. Pull out the outer element 40-2. Take
renewed. care not to tap or knock the element as you remove it.
If necessary, pull out the inner filter 40-3.
!MCAUTION 5 Clean inside housing 40-4 and dust valve 40-5.
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates. 6 Carefully insert the new elements into the canister.
2-3-3-1 Make sure that they are seated correctly.

!MCAUTION 7 Refit cover 40A and fasten the spring clips. Make
sure that dust valve 40-5 is at the bottom.
Do not run the engine when the outer element has
been removed. 8 Connect the induction hose 40H. Make sure the air
16-3-3-1 filter blocked switch connector is fitted. Check all
hoses for condition and tightness.

Fig 40.

3-60 9803/4160-14 3-60

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Cooling System

!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
9-3-3-1_2

Checking the Coolant Level

1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the right side
engine cover.

2 Check the coolant level in the header tank 41A. The

level should be between the MAX and MIN marks (1/
3 to 2/3 full). If not, continue with steps 3 to 6. Fig 42. 446

3 Close the engine cover. Top up the coolant system

through the filler cap. Access to the filler cap is
through a hole in the engine cover above the filler
cap.

4 Refit the filler cap and make sure it is tight.

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

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

Fig 41. 426, 436

3-61 9803/4160-14 3-61

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Coolant Mixtures
To prevent the coolant freezing in cold conditions,
antifreeze must be added. JCB Universal Antifreeze will
give protection down to the temperatures shown in the
table.

Antifreeze Solution Starts to freeze at

55% -36°C (-33°F)

Never use less than 50% solution otherwise there will not
be enough corrosion protection.

Never use more than 60% solution otherwise the cooling

system may be damaged.

Leave the antifreeze in all the year round as it gives

protection against corrosion.

Check the strength of antifreeze solution at least once a

year, preferably at the start of the cold period. Always
renew the antifreeze every two years.

A 50% antifreeze mixture should be used even if frost

protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.

!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1

Anti-Corrosion Additives (446)

To provide sufficient corrosion protection, supplemental

coolant additive (SCA) must be added to the coolant
mixture. The coolant filter provides the required amount of
SCA, provided the filter is replaced at regular intervals.

3-62 9803/4160-14 3-62

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Changing the Coolant

1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the left side
engine cover.

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

2 Carefully loosen cap. Let any pressure escape. Fig 43.

Remove the cap.

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

3 Remove drain plug 43B from engine block.

4 Remove the drain plug at the base of the radiator and

drain the coolant.

5 Flush the system using clean water.

6 Clean and refit the engine block and radiator drain

plugs.

7 Fill the system using the necessary mix of water and

anti-freeze.

8 Refit the filler cap.

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

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

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

3-63 9803/4160-14 3-63

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Draining and Refilling the Coolant (446)

1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the left side
engine cover.

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

Fig 44.
2 Access to the filler cap is through a hole in the engine
cover above the filler cap. Carefully loosen cap. Let
7 Fill the system slowly with the mixture to prevent air
any pressure escape. Remove the cap.
locks. Wait 2 to 3 minutes to allow air to be vented and
top up the header tank to 1/3 full. Do not fit the filler
!MCAUTION cap at this stage.
Keep your face away from the drain hole when
8 Run the engine for 5 minutes at the normal running
removing the drain plug.
temperature. Stop the engine and allow to cool.
2-3-3-4

9 Drain the cooling system, checking that the coolant is

3 Remove the bottom hose 44A from transmission
not dirty. If it is, repeat the flushing process (steps 6 to
cooler 44B and drain the coolant.
9).Refill the system as described at step 7 but using
pre-mixed water/antifreeze solution (as specified in
4 Flush the system using clean water.
Coolant Mixtures ( 3-62)). Do not overfill. Fit
the filler cap.
5 Refit hose 44A.
Note: A 50% antifreeze mixture must be used even if frost
6 Prepare a mixture of water and sodium carbonate.
protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.
Note: Use 1.0 lb (0.5 kg) of sodium carbonate for every 23
litre (5.0 UK Gal).
10 Run the engine for a while to raise the coolant to
working temperature and pressure. Stop the engine
and check for leaks.

Note: Make sure the heater control is in the hot position

before running the engine. This will ensure that the coolant
mixture circulates through the entire cooling system.

3-64 9803/4160-14 3-64

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Changing the Coolant Filter (446)

1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the right side
engine cover.

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

2 Carefully loosen filler cap. Let any pressure escape.

Remove the cap.

3 Close bleed tap 46A to prevent loss of coolant.

4 Remove the coolant filter by unscrewing anti-

clockwise.

5 Clean the filter head area.

6 Test the coolant

7 Smear clean oil on the new coolant filter seal.

Fig 45.
8 Screw on the filter until it just contacts the filter head.

9 Turn the filter a minimum further 3/4 of a turn.

10 Open bleed tap 46A.

3-65 9803/4160-14 3-65

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Testing the Coolant Filter (446)

Carry out the coolant test at the same time as the
scheduled coolant filter change.

Note: The coolant sample must NOT be taken from the

header tank.

1 Park the machine on level ground. Engage the

parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the right side
engine cover.

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

2 Carry out steps 2 to 6 of Changing the Coolant

Filter (446) ( 3-65).

3 Open bleed tap 46A and collect 1/4 pt (250ml) of

coolant in a clean container.

4 Test the coolant using a new test strip from the kit. Fig 46.

5 Check the strip results and act accordingly.

6 Carry our steps 6 to 9 of Changing the Coolant

Filter (446) ( 3-65).

3-66 9803/4160-14 3-66

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Checking the Coolant Level (426 from S/ Coolant Mixtures (426 from S/N 532500
N 532500 and 436 from S/N 534200) and 436 from S/N 534200)

!MWARNING To prevent the coolant freezing in cold conditions,

antifreeze must be added. JCB Universal Antifreeze will
The cooling system is pressurised when the coolant is give protection down to the temperatures shown in the
hot. When you remove the cap, hot coolant can spray table.
out and burn you. Make sure that the engine is cool
before you work on the cooling system. Antifreeze Solution Starts to freeze at
9-3-3-1_2
55% -36°C (-33°F)
1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop Never use less than 50% solution otherwise there will not
the engine and let it cool down. Open the right side be enough corrosion protection.
engine cover.
Never use more than 60% solution otherwise the cooling
2 Check the coolant level in the header tank 47A. The system may be damaged.
level should be between the MAX and MIN marks. If
not, continue with steps 3 to 5. Leave the antifreeze in all the year round as it gives
protection against corrosion.
3 Close the engine cover. Top up the coolant system
through the filler cap. Access to the filler cap is Check the strength of antifreeze solution at least once a
through a hole in the engine cover above the filler year, preferably at the start of the cold period. Always
cap. renew the antifreeze every two years.

4 Refit the filler cap and make sure it is tight. A 50% antifreeze mixture should be used even if frost
protection is not needed. This gives protection against
5 Run the engine for a while to raise the coolant to corrosion and raises the coolant's boiling point.
working temperature and pressure. Stop the engine
and check for leaks.
!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1

Fig 47.

3-67 9803/4160-14 3-67

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Changing the Coolant (426 from S/N 8 Fill the system using the necessary mix of water and
anti-freeze.
532500 and 436 from S/N 534200)
Note: It is recommended that the cooling system be filled
!MWARNING 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
Make the machine safe before working underneath it. trapped in the system.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put 9 Refit the filler cap.
the transmission in neutral and stop the engine. Block
both sides of all four wheels. 10 Check for leaks. Close and lock the engine cover.

Disconnect the battery, to prevent the engine being 11 Run the engine for a while to raise the coolant to
started while you are beneath the machine. working temperature and pressure. Stop the engine
GEN-4-1_1 and check for leaks.
1 Park the machine on level ground. Engage the Table 15. Torque Settings
parking brake. Put the transmission in neutral. Stop
Item Nm kgf m lbf ft
the engine and let it cool down. Open the left side
engine cover. B 55 5.6 40

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

2 Carefully loosen cap. Let any pressure escape.

Remove the cap.

!MCAUTION
Keep your face away from the drain hole when
removing the drain plug. Fig 48.
2-3-3-4

3 Remove drain plug 48A from the engine block.

4 Remove the drain plug 49B from the engine coolant

section of the cooling pack.

5 Flush the system using clean water.

6 Clean and refit the engine block drain plug 48A.

7 Renew the aluminium washer on the cooling pack

drain plug 49B. Refit the plug and torque tighten. (See
Torque Settings.)

3-68 9803/4160-14 3-68

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Fig 49.

3-69 9803/4160-14 3-69

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Checking the Coolant Level - 426 from Anti-Corrosion Additives - 426 from
M1231500, 436 from M1305000 M1231500, 436 from M1305000
1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
!MWARNING
the engine and let it cool down. Open the rightside Antifreeze can be harmful. Obey the manufacturer's
engine cover. instructions when handling full strength or diluted
antifreeze.
2 Check that the coolant is visible in the header tank 7-3-4-4_1
50A. The level should be between 1/3 and 2/3 full. If
not, continue with steps 3 to 5. To provide sufficient corrosion protection, supplemental
coolant additive (SCA) must be added to the coolant
3 Close the engine cover. Top up the coolant system mixture. The coolant filter provides the required amount of
through the filler cap. Access to the filler cap is SCA, provided the filter is replaced at regular intervals.
through a hole in the engine cover above the filler
cap.

4 Refit the filler cap and make sure it is tight.

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

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

Fig 50.

3-70 9803/4160-14 3-70

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cooling System

Draining and Refilling the Coolant - 426 10 Refill the system as described at step 7 but using pre-
mixed water/antifreeze solution (as specified in
from M1231500, 436 from M1305000 Coolant Mixtures ( 3-62)). Do not overfill. Fit
the filler cap.
1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
Note: A 50% antifreeze mixture must be used even if frost
the engine and let it cool down. Open the leftside
protection is not needed. This gives protection against
engine cover.
corrosion and raises the coolant's boiling point.

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

working temperature and pressure. Stop the engine
Hot Coolant and check for leaks.
The cooling system is pressurised when the engine is
hot. Hot coolant can spray out when you remove the Note: Make sure the heater control is in the hot position
filler cap. Let the system cool before removing the before running the engine. This will ensure that the coolant
filler cap. To remove the cap; turn it to the first notch mixture circulates through the entire cooling system.
and let the system pressure escape, then remove the
cap.
INT-3-2-9_1

2 Access to the filler cap is through a hole in the engine

cover above the filler cap. Carefully loosen cap. Let
any pressure escape. Remove the cap.

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

3 Remove drain plug from the radiator drain extension

and drain the coolant.

4 Flush the system using clean water.

5 Refit drain plug.

6 Prepare a mixture of water and sodium carbonate.

Note: Use 1.0 lb (0.5 kg) of sodium carbonate for every 23

litre (5.0 UKGal).

7 Fill the system slowly with the mixture to prevent air

locks. Wait 2 to 3 minutes to allow air to be vented and
top up the header tank to 1/3 full. Do not fit the filler
cap at this stage.

8 Run the engine for 5 minutes at the normal running

temperature. Stop the engine and allow to cool.

9 Drain the cooling system, checking that the coolant is

not dirty. If it is, repeat the flushing process (steps 6 to
9).

3-71 9803/4160-14 3-71

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Fan Belts

Alternator Drive Belts

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

Adjusting

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Open the left side engine cover.

4 Loosen bolts 51A, 51B and 51C holding the

alternator.

!MCAUTION
Any leverage required to position the alternator must
be applied at the drive end bracket only, using a
wooden lever.
8-3-2-1 Fig 51.
5 Adjust the fan belt by positioning the alternator to give
10 mm (3/8 in) slack at the mid point of the longest run
on the tighter of the two belts.

6 Tighten bolts 51A, 51B and 51C.

Note: Make sure bolt 51C is the last bolt to be tightened.

7 Close and lock the engine cover.

3-72 9803/4160-14 3-72

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Air Conditioning Compressor Drive Belt

Adjusting

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

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Open the right side engine panel.

4 Loosen pivot bolt 52A (not shown). Loosen bolts 52B

and 52C.

5 Adjust the belt by positioning the compressor to give

5 mm (3/16 in) slack at the mid point of the longest
run.

6 Tighten bolts 52B and 52C. Tighten pivot bolt 52A.

Fig 52.
7 Close and lock the engine panel.

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

3-73 9803/4160-14 3-73

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Engine Drive Belt Check the belt tension

Inspection and Belt Tension 1 The maximum deflection on the longest run of the belt
as at 54D should be 9.5 to 12.7 mm (0.375 to 0.5 in).
If the deflection is excessive, fit a replacement.
!MWARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5

Inspection

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Open the engine side covers.

4 Inspect the belt for damage.

a Cracks across the belt width 53A are acceptable.

Fig 54.
b Cracks across the belt which intersect those in the
direction of the belt length 53B are not Renew the Belt and Check the Belt Tensioner
acceptable.
1 Slacken the tension of the air conditioning
c Renew the belt if it has unacceptable cracks or if compressor drive belt 55E and lift the belt clear of its
it is frayed or has pieces of material missing as at drive pulley. (To refit see Air Conditioning
53C. Compressor Drive Belt ( 3-73).)

2 Using a 3/8 in square drive inserted in the belt

tensioner as shown at 55F, lever the tensioner in the
direction of the arrow to allow the belt to be lifted
clear. Do not use excessive force or the tensioner will
be damaged.

3 Before fitting a new belt, check that the tensioner

roller rotates smoothly and that there is no side play
in the bearings.

4 Fit the new belt and allow the tensioner to return to its
normal position.

5 Check that the tensioner securing bolt 55G is

tightened to 43 Nm (32 lbf/ft)
Fig 53.
6 Refit the air conditioning compressor drive belt. (see
Air Conditioning Compressor Drive
Belt ( 3-73))

7 Close and lock the engine side covers.

3-74 9803/4160-14 3-74

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Fig 55.

3-75 9803/4160-14 3-75

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Air Conditioning Compressor Drive Belt

(426 from S/N 532500, 436 from S/N
534200 and 446 to S/N 540011)
Adjusting the Compressor Drive Belt

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

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Open the right side engine panel.

4 Loosen pivot bolt 56A (Not shown). Loosen bolts 56B

and 56C.

5 Adjust the belt by positioning the compressor to give

5 mm (3/16 in) slack at the mid point of the longest
run.

6 Tighten bolts 56B and 56C. Tighten pivot bolt 56A.

7 Close and lock the engine panel.

Fig 56. 436

Note: The adjusting bracket on the 436 from serial number

534200 incorporates a in square hole at position 56D. This
is for the insertion of in drive ratchet to assist with the
tensioning of the drive belt. Do Not Over Tighten the belt.

3-76 9803/4160-14 3-76

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Fig 57. 426 and 446

3-77 9803/4160-14 3-77

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fan Belts

Adjusting the Compressor Belt - 426

from M1231500, 436 from M1305000

!MWARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.

2-3-3-5

Note: The engine illustrated is the type fitted to early 

machines. The engine on later machines looks different
but the procedure is not affected.

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Open the right side engine panel.

4 Loosen pivot bolt 58A (Not shown). Loosen bolts 58B

and 58C.
Fig 58.
5 Adjust the belt by positioning the compressor to give
5 mm (3/16 in) slack at the mid point of the longest
run.

6 Tighten bolts 58B and 58C. Tighten pivot bolt 58A.

7 Close and lock the engine panel.

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

3-78 9803/4160-14 3-78

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Fuel System

Types of Fuel – ASTM D975-91 Class 1-1DA.

T3-007_2 – JP7, MIL T38219 XF63.
Use good quality diesel fuel to get the correct power and – NATO F63.
performance from your engine.
Sulphur Content
Recommended Fuel Specification

– EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4. !MCAUTION

– BS2869 Class A2. A combination of water and sulphur will have a
– ASTM D975-91 Class 2-2DA, US DF1, US DF2, US corrosive chemical effect on fuel injection equipment.
DFA. It is essential that water is eradicated from the fuel
system when high sulphur fuels are used.
– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade
ENG-3-2
3.
High sulphur content can cause engine wear. (High
Note: Where low sulphur/low aromatic fuels are used it is
sulphur fuel is not normally found in North America,
important that lubricity additives are used. The additives
Europe or Australia.) If you have to use high sulphur fuel
listed below are advertised as being suitable for bringing
you must change the engine oil more frequently.
the lubricity levels of kerosene/low sulphur fuels up to
those of diesel fuels. They have not been tested or
Table 16.
approved by the engine manufacturer. They should be
added by your fuel supplier who should understand the Percentage of sulphur in Oil Change Interval
concentration level necessary. the fuel (%)
Less than 0.5 Normal
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), 0.5 to 1.0 0.75 of normal
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels. More than 1.0 0.50 of normal

2 Lubrizol 539N. Dosage (on Swedish low sulphur fuel) Aviation Kerosene Fuels
250 ppm.
Note: Aviation kerosene fuels are not approved and their
3 Paradyne 7505 (from Infineum). Dosage 500 ppm use may cause damage to components. Warranty will not
(0.05%). be allowed on any component where damage is found to
have been caused by the use of aviation kerosene.
!MCAUTION Low Temperature Fuels
Consult your fuel supplier or JCB distributor about the
suitability of any fuel you are unsure of. Special winter fuels may be available for engine operation
GEN-9-2 at temperatures below 0°C (32°F). These fuels have a
lower viscosity. They also limit wax formation in the fuel at
Acceptable Fuel Specification low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter.)
!MCAUTION Fatty Acid Methyl Ester Fuels as a Replacement
The fuel specification below is acceptable, however for diesel Fuels
this fuel may reduce the life of the fuel injection
equipment. The use of this fuel may also affect the Fuel resources such as Rape Methyl Ester and Soybean
engine performance. Methyl ester, collectively known as Fatty Acid Methyl
GEN-9-3

3-79 9803/4160-14 3-79

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System
Esters are being used as alternatives and extenders for Filling the Tank
mineral oil.

Fatty Acid Methyl Esters must conform to certain !MWARNING

standards to be of acceptable quality, just as mineral oils Diesel Fuel
do at present. Diesel fuel is flammable; keep naked flames away from
the fuel system. Do not smoke while refuelling or
Consult your JCB distributor for advice about the use of working on the fuel system. Do not refuel with the
Fatty Acid Methyl Ester fuels, as improper application may engine running. There could be a fire and injury if you
impair engine performance. do not follow these precautions.
INT-3-2-2_1
!MWARNING At the end of every working day, fill the tank with the correct
Diesel Fuel type of fuel. This will prevent overnight condensation from
Diesel fuel is flammable; keep naked flames away from developing in the fuel.
the fuel system. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the We recommend that, if possible, you lock the fuel cap to
engine running. There could be a fire and injury if you prevent theft and tampering.
do not follow these precautions.
INT-3-2-2_1

Petrol

!MWARNING
Petrol
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6

3-80 9803/4160-14 3-80

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Fuel Filters (Standard)

1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Open the right side engine cover.

3 Drain off any water in the bowl 59B by turning valve

59A.

4 Repeat for second filter.

5 Close and lock the engine cover.

!MCAUTION
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.
2-3-3-11

Fig 59.

3-81 9803/4160-14 3-81

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Changing the Fuel Filter Elements

(Standard)
1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Open the right side engine cover.

3 Hold bowl 59B and unscrew bolt 59C, remove bowl

and filter element 59E.

4 Inspect seals 59D and renew if damaged.

5 Fit new element 59E, sealing rings 59D and bowl

59B. Make sure seals 59D are seated correctly.

6 Tighten bolt 59C.

7 Repeat for second filter.

8 Bleed the fuel system. See Bleeding the

System ( 3-84).

9 Close and lock the engine cover.

3-82 9803/4160-14 3-82

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Sedimenter Bowl Cleaning the Sedimenter Bowl

1 Apply the parking brake, put the transmission in If bowl 60B contains sediment carry out the following:-
neutral and stop the engine.
1 Hold the bowl 60B and unscrew nut 60C.
2 Open the left side engine cover.
2 Remove the bowl, and wash in clean fuel.
3 Drain off any water in the bowl by turning tap 60A and
slacken screw 60D. 3 Refit the bowl. Make sure the gasket is in good
condition and positioned correctly.
4 Make sure tap 60A is turned off and secure.
4 Re-tighten nut 60C, taking care not to over-tighten.
5 Close and lock the engine cover.
5 Bleed the fuel system. See Bleeding the
!MCAUTION System ( 3-84).

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.
2-3-3-11

Fig 60.

3-83 9803/4160-14 3-83

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Bleeding the System

!MCAUTION
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.
2-3-3-11

If the engine fails to start, misfires or if any part of the fuel

system has been disconnected or emptied, bleed the
system as follows:

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

2 Open the left side engine cover.

3 Make sure that there is enough fuel in the fuel tank.

Fig 61.
4 Turn the starter key to the IGN position.

5 Operate the fuel lift pump priming lever 61X slowly for
about two minutes.

6 Turn the starter key fully clockwise to the HS position

until the engine starts.

Note: If the engine runs smoothly for a short time and then
begins to run roughly or stops, check again for air in the
fuel system.

7 Close and lock the engine cover.

3-84 9803/4160-14 3-84

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Fuel Filter (Spin-on)

1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Open the right side engine cover.

3 Drain off any water in the bowl 62A by turning tap

62B.

4 Repeat for second filter.

5 Close and lock the engine cover.

!MCAUTION
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.
2-3-3-11

Changing the Fuel Filter Element (Spin-

on)
1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Open the right side engine cover.

3 Unscrew the filter element 62A, the element is hand

tight but may require a strap wrench to remove. The
filter will be full of fuel.

4 Repeat for second filter.

5 To assist with bleeding fill the filter element with fuel

before fitting. Install the filter element 62A, hand tight
only. Check for leaks.
Fig 62.
6 Bleed the fuel system. See Bleeding the
System ( 3-84).

7 Close and lock the engine cover.

3-85 9803/4160-14 3-85

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Fuel Filter (446) Changing the Fuel Filter Element (446)
1 Apply the parking brake, put the transmission in 1 Apply the parking brake, put the transmission in
neutral and stop the engine. neutral and stop the engine.

2 Open the right side engine cover. 2 Open the right side engine cover.

3 Drain off any water in the bowl 63B by turning valve 3 Unscrew the filter element , the element is hand tight
63A 4 turns anti-clockwise until the valve drops down but may require a strap wrench to remove. The filter
25 mm (1.0 in). will be full of fuel.

4 Push up valve and turn clockwise until closed. Do not 4 To assist with bleeding fill the filter element with fuel
over tighten. before fitting. Install the filter element , hand tight only.
Check for leaks.
5 Close and lock the engine cover.
5 Bleed the fuel system. See Bleeding the
!MCAUTION System ( 3-84).

Running the engine with air in the system could 6 Close and lock the engine cover.
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11

Fig 63.

3-86 9803/4160-14 3-86

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Sedimenter Bowl (426 from

S/N 532500, 436 from S/N 534200 and 446
to 540011)
1 Apply the parking brake, put the transmission in
neutral and stop the engine.

2 Open the left side engine cover.

3 Drain off any water in the bowl by turning tap 64A and
slacken screw 64E.

4 Make sure tap 64A is turned off and secure. Tighten

screw 64E.

5 Close and lock the engine cover.

!MCAUTION
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.
2-3-3-11

Fig 64.

3-87 9803/4160-14 3-87

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Cleaning the Sedimenter Bowl (426 from

S/N 532500, 436 from S/N 534200 and 446
to S/N 540011)
If bowl 64B contains sediment carry out the following:-

1 Hold the bowl 64B and unscrew domed nut 64C.

2 Remove the bowl, and wash in clean fuel.

3 Clean strainer 64D.

4 Refit the bowl. Make sure the gasket is in good

condition and positioned correctly.

5 Re-tighten nut 64C, taking care not to over-tighten.

6 Bleed the fuel system. See Bleeding the

System ( 3-84).

3-88 9803/4160-14 3-88

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Bleeding the System (446) a Slacken one of the injector feed pipe nuts 65D.

b Crank the engine, when air free fuel flows from the
!MCAUTION connection, tighten the nut.
Running the engine with air in the system could
damage the fuel injection pump. After maintenance, c Repeat steps a and b at each injector in turn until
the system must be bled to remove any air. the engine runs smoothly.
2-3-3-11
7 Close and lock the engine cover.
If the engine fails to start, misfires or if any part of the fuel
system has been disconnected or emptied, bleed the
system as follows:

Note: Small amounts of air will be vented automatically at

the injection pump. Manual bleeding should not be
required after changing the filters if they are filled with fuel
before fitting.

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

2 Make sure that there is enough fuel in the fuel tank.

3 Open the right side engine cover.

!MWARNING
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job. Bleeding
a hot engine could cause fuel to spill on to a hot
exhaust manifold creating a danger of fire.
13-3-1-16

4 Open bleed screw 65A.

5 Operate the priming plunger 65B until air free fuel

flows from the bleed screw. Tighten the bleed screw.

!MWARNING
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.
2-3-3-8

6 Bleed the injectors

3-89 9803/4160-14 3-89

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Fig 65.

3-90 9803/4160-14 3-90

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Fuel Filter (426 from S/N Changing the Fuel Filter Element (426
532500 and 436 from S/N 534200) from S/N 532500 and 436 from S/N
534200)
1 Apply the parking brake, put the transmission in
neutral and stop the engine. 1 Apply the parking brake, put the transmission in
neutral and stop the engine.
2 Open the right side engine cover.
2 Open the right side engine cover.
3 Drain off any water in the bowl 66B by turning valve
66A 4 turns anti-clockwise until the valve drops down 3 Unscrew the filter element, the element is hand tight
25 mm (1.0 in). but may require a strap wrench to remove. The filter
will be full of fuel.
4 Push up valve and turn clockwise until closed. Do not
over tighten. 4 To assist with bleeding fill the filter element with fuel
before fitting. Install the filter element, hand tight only.
5 Close and lock the engine cover. Check for leaks.

!MCAUTION 5 Bleed the fuel system. See

System ( 3-84).
Bleeding the

Running the engine with air in the system could

damage the fuel injection pump. After maintenance, 6 Close and lock the engine cover.
the system must be bled to remove any air.
2-3-3-11

Fig 66.

3-91 9803/4160-14 3-91

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Bleeding the System (426 from S/N

532500 and 436 from S/N 534200)

!MCAUTION
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.
2-3-3-11

If the engine fails to start, misfires or if any part of the fuel

system has been disconnected or emptied, bleed the
system as follows:

Note: Small amounts of air will be vented automatically at

the injection pump. Manual bleeding should not be
required after changing the filters if they are filled with fuel
Fig 67.
before fitting.

1 Apply the parking brake, put the transmission in !MWARNING

neutral and stop the engine.
To bleed the injectors you must turn the engine. When
the engine is turning, there are parts rotating in the
2 Make sure that there is enough fuel in the fuel tank.
engine compartment.
3 Open the right side engine cover.
Before starting this job make sure that you have no
loose clothing (cuffs, ties etc) which could get caught
!MWARNING in rotating parts.
Hot oil and engine components can burn you. Make
When the engine is turning, keep clear of rotating
sure the engine is cool before doing this job. Bleeding
parts.
a hot engine could cause fuel to spill on to a hot
2-3-3-8
exhaust manifold creating a danger of fire.
13-3-1-16
6 Bleed the injectors
4 Open bleed screw 67A.
a Slacken one of the injector feed pipe nuts 68C.
5 Operate the priming plunger 67B until air free fuel
b Crank the engine, when air free fuel flows from the
flows from the bleed screw. Tighten the bleed screw.
connection, tighten the nut.

c Repeat steps a and b at each injector in turn until

the engine runs smoothly.

7 Close and lock the engine cover.

3-92 9803/4160-14 3-92

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Fig 68.

3-93 9803/4160-14 3-93

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Fuel Filter - 426 from Changing the Fuel Filter Element - 426
M1231500, 436 from M1305000 from M1231500, 436 from M1305000
1 Apply the parking brake, put the transmission in 1 Apply the parking brake, put the transmission in
neutral and stop the engine. neutral and stop the engine.

2 Open the right side engine cover. 2 Open the right side engine cover.

3 Drain off any water in the bowl 69B by turning valve 3 Unscrew the filter element 69B, the element is hand
69A 4 turns anti-clockwise until the valve drops down tight but may require a strap wrench to remove. The
25 mm (1.0 in). filter will be full of fuel.

4 Push up valve and turn clockwise until closed. Do not 4 To assist with bleeding, fill the filter element with fuel
over tighten. before fitting. Install filter element, hand tight only.
Check for leaks.
5 Close and lock the engine cover.
5 Bleed the fuel system. Bleeding the
!MCAUTION System ( 3-84).

Running the engine with air in the system could 6 Close and lock the engine cover.
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11

Fig 69.

3-94 9803/4160-14 3-94

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Draining the Sedimenter Bowl - 426 from Cleaning the Sedimenter Bowl - 426 from
M1231500, 436 from M1305000 M1231500, 436 from M1305000
1 Apply the parking brake, put the transmission in If bowl 70B contains sediment carry out the following:-
neutral and stop the engine.
1 Hold the bowl 70B and unscrew domed nut 70C.
2 Open the rear grille.
2 Remove the bowl, and wash in clean fuel.
3 Drain off any water in the bowl by turning tap 70A and
slacken screw 70E. 3 Clean strainer 70D.

4 Make sure tap 70A is turned off and secure. Tighten 4 Refit the bowl. Make sure the gasket is in good
screw 70E. condition and positioned correctly.

5 Close and lock the rear grille. 5 Re-tighten nut 70C, taking care not to over-tighten.

!MCAUTION 6 Bleed the fuel

System ( 3-84).
system. Bleeding the

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.
2-3-3-11

 




Fig 70.

3-95 9803/4160-14 3-95

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Fuel System

Bleeding the System - 426 from 6 Bleed the injectors

M1231500, 436 from M1305000 a Slacken one of the injector feed pipe nuts 71C.

!MCAUTION b Crank the engine, when air free fuel flows from the
connection, tighten the nut.
Running the engine with air in the system could
damage the fuel injection pump. After maintenance, c Repeat steps a and b at each injector in turn until
the system must be bled to remove any air. the engine runs smoothly.
2-3-3-11
7 Close and lock the engine cover.
If the engine fails to start, misfires or if any part of the fuel
system has been disconnected or emptied, bleed the
system as follows:

Note: Small amounts of air will be vented automatically at

the injection pump. Manual bleeding should not be
required after changing the filters if they are filled with fuel
before fitting.

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

2 Make sure that there is enough fuel in the fuel tank.

3 Open the right side engine cover.

!MWARNING
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job. Bleeding
a hot engine could cause fuel to spill on to a hot
exhaust manifold creating a danger of fire.
13-3-1-16

4 Open bleed screw 71A.

5 Operate the priming plunger 71B until air free fuel

flows from the bleed screw. Tighten the bleed screw.

!MWARNING
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 Fig 71.
loose clothing (cuffs, ties etc) which could get caught
in rotating parts.

When the engine is turning, keep clear of rotating

parts.
2-3-3-8

3-96 9803/4160-14 3-96

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Hydraulic System

Hydraulic System

Checking the Fluid Level

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

1 Apply the parking brake, put the transmission in

neutral, lower the shovel/attachment to the ground.
Make sure it is flat on the ground. Stop the engine.

2 Look at the fluid level in the sight glass 72A. The level Fig 73.
should be visible in the sight glass.

3 If necessary, top up with hydraulic fluid. !MCAUTION

If the fluid is cloudy, then water or air has
4 Open the right side engine cover. Open filler cap 73B. contaminated the system. This could damage the
hydraulic pump. Contact your JCB Distributor
5 Top up the system with hydraulic fluid. See immediately.
Lubricants and Capacities ( 3-14). 12-5-1-4

6 Refit filler cap 73B. Make sure it is secure. Close and Changing the Filter Element
lock the engine cover.

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

1 Open the right side engine cover.

Fig 72.
2 Remove hydraulic tank cap.

3 Unscrew and remove nuts 74C, cover plate 74D and

seal 74E.

3-97 9803/4160-14 3-97

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Hydraulic System
4 Pull out the complete element assembly 74F and
seals 74G and 74H.

5 Remove the nut and spring 74K. Remove the filter

element 74L from the spindle and clean magnets 74J.

6 Fit the new element 74L and the new seals 74G and
74H.

7 Replace the cover plate 74D and tighten nuts 74C to

7 Nm (5 lbf ft).

8 Top up the system with hydraulic fluid. See

Lubricants and Capacities ( 3-14).

9 Refit filler cap. Make sure it is secure. Close and lock

the engine cover.

Fig 74.

3-98 9803/4160-14 3-98

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Hydraulic System

Checking the Fluid Level - 426 from

M1231500, 436 from M1305000
1 Apply the parking brake, put the transmission in
neutral, lower the shovel/attachment to the ground.
Make sure it is flat on the ground. Stop the engine.

2 The level should be visible in the sight glass 75A.

3 If necessary, top up with hydraulic fluid.

4 Open the right side engine cover. Open filler cap 76B.

5 Top up the system with hydraulic fluid, Lubricants

and Capacities - 426 from M1231500 ( 3-21).

6 Refit filler cap 76B. Make sure it is secure. Close the

engine cover.
Fig 76.

Fig 75.

!MCAUTION
If the fluid is cloudy, then water or air has
contaminated the system. This could damage the
hydraulic pump. Contact your JCB Distributor
immediately.
12-5-1-4

3-99 9803/4160-14 3-99

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Hydraulic System

Changing the Filter Element - 426 from

M1231500, 436 from M1305000
 
!MWARNING 
Make the machine safe before working underneath it.
Park the machine on level ground, lower the 
attachments to the ground. Apply the park brake, put 
the transmission in neutral and stop the engine. Block
both sides of all four wheels. 
Disconnect the battery, to prevent the engine being 
started while you are beneath the machine.
GEN-4-1_1 
1 Open the right side top step.

2 Remove hydraulic tank cap.

3 Unscrew and remove nuts 77C, cover plate 77D and

seal 77E. 
4 Pull out the complete element assembly 77F and the
seal. Fig 77.

5 Remove the nut and spring 77K. Remove the filter

element 77L from the spindle and clean magnets 77J.

6 Fit the new element 77L and the new seals 77G and
77H.

7 Replace the cover plate 77D and tighten nuts 77C to

7 Nm (5 lbf ft).

8 Top up the system with hydraulic fluid, Lubricants

and Capacities - 426 from M1231500 ( 3-21).

9 Refit filler cap. Make sure it is secure. Close the right

side top step.

3-100 9803/4160-14 3-100

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Transmission

Transmission

Checking the Oil Level

1 Park the machine on level ground.

2 Apply the parking brake. Lower the loader to the

ground. Put the transmission in neutral and stop the
engine. Chock the wheels then restart the engine,
allowing it to run at idle.

!MWARNING
The procedure below must be carried out with the
engine running. Apply the park brake, block the
wheels and ensure that no-one enters the cab.
SUS-1-1

KEEP YOUR BODY AND CLOTHING CLEAR OF

ROTATING AND HOT PARTS IN THE ENGINE BAY. Fig 78.

3 Open the left side engine cover. Remove, wipe and

replace the dipstick 78A.

Note: Replace the dipstick carefully, the bung should not

be tight in the tube.

4 Make sure the oil is at the correct mark on the

dipstick.

5 If necessary, stop the engine and add recommended

oil at dipstick/filler point 78A.

The dipstick is marked as follows:

HOT - When the engine/transmission is at working

temperature.

COLD - When the engine has been started but has

not warmed up.

6 Close and lock the engine cover.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Transmission

Changing the Oil and Filter

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

1 Place a container that can hold 20 litres (4.5 gal.)

beneath the machine. (To catch the oil).

2 Remove dipstick 79A and drain plug 79B. Allow oil to

drain into the container.

3 Clean and refit plug 79B.

4 Unscrew and discard filter 79C. Clean the mounting

face and lubricate the seal 79D on the new filter with
clean transmission fluid.

5 Fit the new filter - hand tight only.

6 Fill the system with new oil at dipstick/filler point 79A.

Note: Do not fill past the top mark on the dipstick.

Fig 79.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Transmission

Checking the Oil Level

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral.

3 Open the left side engine cover. Remove, wipe and

replace the dipstick 80A.

Note: Turn `T' handle 80D, two full turns anti-clockwise to

release the dipstick. Turn `T' handle 80D, two full turns
clockwise to fasten in position. Check that the dipstick is
secure.

4 Make sure the oil is at the correct mark on the

dipstick.

5 If necessary, add recommended oil at dipstick/filler

point 80A.

The dipstick is marked as follows:

HOT - When the engine/transmission is at working

temperature.

Note: The transmission may overheat if the oil level is

above the HOT mark.

COLD - When the engine/transmission has not

warmed up.

6 Close and lock the engine cover.

Fig 80.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Transmission

Checking the Oil Level (Engine Running)

426 from M1231500, 436 from M1305000
Note: The transmission oil level should be checked only
when the oil is at the correct working temperature.

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral.

!MWARNING
The procedure below must be carried out with the
engine running. Apply the park brake, block the
wheels and ensure that no-one enters the cab.
SUS-1-1

Fig 81.
3 Open the left side engine cover. Remove, wipe and
replace the dipstick 81A.

Note: Turn `T' handle 81D, two full turns anti-clockwise to

release the dipstick. Turn `T' handle 81D, two full turns
clockwise to fasten in position. Check that the dipstick is
secure.

4 Make sure the oil is at the correct mark on the

dipstick.

5 If necessary, add recommended oil at dipstick/filler

point 81A.

Note: The transmission may overheat if the oil level is

above the HOT mark.

6 Close and lock the engine cover.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Transmission

Changing the Oil and Filter

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

1 Place a suitable container beneath the transmission

(to catch the oil).

2 Remove the dipstick 80A/81A and drain plug 82B.

3 Drain the oil. Clean and refit drain plug 82B.

4 Unscrew and discard old filter 82C. Clean the

mounting face and lubricate the seal on the new filter
with clean torque converter fluid.

5 Fit the new filter 82C hand tight only.

6 Fill the system with new oil at dipstick/filler point 80A/ Fig 82.
81A.

Note: Do not fill past the top mark on the dipstick.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Front and Rear Axles

Front and Rear Axles

Checking the Differential Oil Level 2 Remove fill/level plug 83A and its seal.

3 Place a suitable container beneath the drain plug 83B

!MWARNING (to catch the oil).
Make the machine safe before working underneath it.
Park the machine on level ground, lower the 4 Remove drain plug 83B. Allow the oil to drain fully.
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.
!MCAUTION
Oil will gush from the hole when the drain plug is
Disconnect the battery, to prevent the engine being removed. Keep to one side when you remove the plug.
started while you are beneath the machine. 2-3-4-2

GEN-4-1_1
5 Clean and refit drain plug 83B and its seal. Plug 83B
is magnetic, make sure all debris is removed. Tighten
!MCAUTION to 85 Nm (60 lbf ft).
The axle oil level must be checked with the machine
level, otherwise a false indication of the amount of oil 6 Fill the axle with the recommended oil through fill/
in the axle will be given. level plug 83A.
16-3-5-3
7 Clean and refit fill/level plug 83A and its seal. Tighten
1 Clean the area around fill/level plug 83A. to 85 Nm (60 lbf ft).

2 Remove fill/level plug 83A and its seal, oil should be

level with the bottom of the hole.

3 Top up with the recommended oil if necessary.

4 Clean and refit fill/level plug 83A and its seal. Tighten
to 85 Nm (60 lbf ft).

Note: The 436 axle is shown, the 426 axle filler plug is at
the opposite side.

Draining and Refilling the Differential Oil

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the Fig 83.
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

1 Clean the area around fill/level plug 83A.

3-106 9803/4160-14 3-106

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Front and Rear Axles

Checking the Hub Oil Level

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

1 Make sure the OIL LEVEL mark on the hub is

horizontal, as shown at 84B.

2 Clean the area around fill/drain plug 84A.

3 Remove fill/drain plug 84A and its seal, oil should be

level with the bottom of the hole.

4 Top up with the recommended oil if necessary.

5 Clean and refit fill/drain plug 84A and its seal. Tighten
to 85 Nm (60 lbf ft).

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

hubs.

Fig 84.

3-107 9803/4160-14 3-107

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Front and Rear Axles

Draining and Refilling the Hub Oil

!MWARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the
attachments to the ground. Apply the park brake, put
the transmission in neutral and stop the engine. Block
both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.
GEN-4-1_1

1 Make sure both fill/drain plug 85A are at the bottom,

as shown at 85C.

2 Clean the area around fill/drain plug 85A.

3 Remove fill/drain plug 85A and its seal, drain the oil
into a suitable container. Allow the oil to drain fully.

!MCAUTION
There will be no oil in the hub when the machine is
driven forward. Only drive the machine forward one Fig 85.
quarter revolution of the wheel. Do not drive the
machine more than is necessary.
4-3-5-1

4 Drive the machine slowly forward to bring the OIL

LEVEL mark on the hubs into the horizontal position,
as shown at 85B.

5 Fill the hub with the recommended oil through fill/

drain plug 85A, until oil starts to dribble out.

6 Clean and refit fill/drain plug 85A and its seal. Tighten
to 85 Nm (60 lbf ft).

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

hubs.

3-108 9803/4160-14 3-108

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cab Heater Filters

Cab Heater Filters

Cleaning the Intake Filter (Early Cleaning the Intake Filter (Early
Machines Vairant 1) Machines Variant 2)
Note: Later machines are fitted with a different 1 Park the machine on level ground. Engage the
arrangement of cab heater filter to that on earlier parking brake. Put the transmission in neutral. Lower
machines. Use the procedure to suit your machine. the attachments to the ground. Stop the engine.
Remove the starter key.
!MCAUTION 2 To gain access to the cab heater air filter 87A, remove
The filter may be filled with dust. Wear goggles and a bolts 87B, open panel 87C.
face mask when removing the filter.
2-3-3-6 3 Open fasteners at 87D, remove plate 87E, remove
the filter, shake out the loose dust and clean using low
1 Park the machine on level ground. Engage the pressure compressed air. Renew the filter if
parking brake. Put the transmission in neutral. Lower damaged.
the attachments to the ground. Stop the engine.
Remove the starter key. 4 Refit filter 87A and plate 87E, close panel 87C and fit
bolts 87B.
2 To gain access to the cab heater air filter 86A, remove
bolts 86B, open panel 86C.

3 Remove the filter and shake out the loose dust. Wash
the filter in warm soapy water.

4 Refit the filter, close panel 86C and fit bolts 86B.

Note: Make sure the filter is dry before refitting.

Fig 87.

Fig 86.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cab Heater Filters

Cleaning the Intake Filter (Later Cleaning the Recirculation Filters

Machines)
!MCAUTION
!MCAUTION The filter may be filled with dust. Wear goggles and a
The filter may be filled with dust. Wear goggles and a face mask when removing the filter.
face mask when removing the filter. 2-3-3-6

2-3-3-6
1 Park the machine on level ground. Engage the
1 Park the machine on level ground. Engage the parking brake. Put the transmission in neutral. Lower
parking brake. Put the transmission in neutral. Lower the attachments to the ground. Stop the engine.
the attachments to the ground. Stop the engine. Remove the starter key.
Remove the starter key.
2 To gain access to the cab recirculation air filters 89F,
2 To gain access to the cab heater air filter 88A, unlock turn fasteners 89G one quarter turn anti-clockwise
88B, open panel 88C. and remove grille 89H.

3 Open fasteners at 88D, remove plate 88E, remove 3 Remove the filters 89F, shake out the loose dust and
the filter, shake out the loose dust and clean using low clean using low pressure compressed air. Renew the
pressure compressed air. Renew the filter if filter if damaged.
damaged.
4 Refit filters 89F and grille 89H, push in and turn
4 Refit filter 88A and plate 88E, close panel 88C and fasteners 89G one quarter turn clockwise. Make sure
lock 88B. that the grille is secure.

Fig 89.
Fig 88.

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 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cab Heater Filters

Cleaning the Intake Filter

Note: Smoothshift transmissions, 426 machines from
Serial No. 532100; 436 machines from Serial No. 533700.

!MCAUTION
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6

1 Park the machine on level ground. Engage the

parking brake. Put the transmission in neutral. Lower
the attachments to the ground. Stop the engine.
Remove the starter key.

2 To gain access to the cab heater air filter, unlock 90B,

open panel 90C. Turn fastener 90A one quarter turn
anti-clockwise and remove cover 90D.

3 Remove the filter, shake out the loose dust and clean
using low pressure compressed air. Renew the filter if
damaged.

Note: Make sure to replace the filter in the correct location. Fig 90.
The short filter must always be fitted in the rear slot.

4 Refit cover 90D, Turn fastener 90A one quarter turn

clockwise. Close panel 90C and lock 90B.

3-111 9803/4160-14 3-111

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cab Heater Filters

Cleaning the Recirculation Filter

!MCAUTION
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6

1 Park the machine on level ground. Engage the

parking brake. Put the transmission in neutral. Lower
the attachments to the ground. Stop the engine.
Remove the starter key.

2 To gain access to the cab recirculation air filter 91F,

turn fastener 91G one quarter turn anti-clockwise and
remove cover 91H.

3 Remove the filter 91F, shake out the loose dust and
clean using low pressure compressed air. Renew the
filter if damaged.

4 Wash filter 91F in warm water with mild detergent.

Rinse all trace of detergent from filter. Make sure filter
is dry before refitting.

5 Refit filter 91F and cover 91H, make sure bottom lug
on cover is located. Push in and turn fastener 91G
one quarter turn clockwise. Make sure that the cover
is secure.

!MCAUTION
The machine must not be run with the intake filter(s)
removed otherwise damage will be caused to the Fig 91.
evaporator matrix.
0029

3-112 9803/4160-14 3-112

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Cab Heater Filters

Cleaning the Intake Filter - 426 from

M1231500, 436 from M1305000 

!MCAUTION 
The filter may be filled with dust. Wear goggles and a
face mask when removing the filter.
2-3-3-6

1 Park the machine on level ground. Engage the

parking brake. Put the transmission in neutral. Lower
the attachments to the ground. Stop the engine.
Remove the starter key.

2 To gain access to the cab heater air filter 92A, open

heater door Opening the Heater Door ( 3-30).

3 Open fasteners at 92B, remove cover 92C.

4 Remove filter A and shake out the loose dust and

clean using low pressure compressed air. Renew the 

filter if damaged.
Fig 92.
Note: An additional filter D may be fitted behind filter A, if
applicable, remove filter D by pulling tag provided.
Magnetic strips hold the filter in place. Refit the filter
making sure it is located correctly. Renew the filter if
damaged.

5 Refit filter A, close heater door.

Fig 93.

3-113 9803/4160-14 3-113

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Windscreen Washer

Windscreen Washer

426 436 From S/N 534200

To gain access to the washer bottle 94A, open the left hand To gain access to the washer bottle 95B, open the right
side engine cover. The washer bottle is located between hand side engine cover. The washer bottle is attached to
the cab and the engine compartment. the engine cover front bulkhead.

Fill the windscreen washer bottle with a suitable liquid. Fill the windscreen washer bottle with a suitable liquid.
The liquid should contain a de-icing fluid to prevent it The liquid should contain a de-icing fluid to prevent it
freezing. Do not use engine coolant antifreeze. freezing. Do not use engine coolant antifreeze.

On completion, close and secure the engine cover. On completion, close and secure the engine cover.

Fig 94.

Fig 95.

3-114 9803/4160-14 3-114

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Windscreen Washer

Replenishing - 426 from M1231500, 436

from M1305000

Fig 96.

To gain access to the washer bottle A, open the heater

compartment door. Opening the Heater Door ( 3-30)
The washer bottle is located inside.

Fill the windscreen washer bottle with a suitable liquid.

The liquid should contain a de-icing fluid to prevent it
freezing. Do not use engine coolant antifreeze.

On completion, close and lock the access cover.

3-115 9803/4160-14 3-115

 Section 3 - Routing Maintenance
Routine Maintenance (426 up to Ser. No. 1295000, 436 up to Ser. No. 1410000)
Windscreen Washer

Page left intentionally blank

3-116 9803/4160-14 3-116

 Section 3 - Routine Maintenance

Routine Maintenance (426 from Ser. No. 1295000,

436 from Ser. No. 1410000)
Service Requirements

Introduction encounter a problem however, you should contact your

T3-002
Distributor's Service Department who are there to help
Your machine has been designed and built to give you!
maximum performance, economy and ease of use under a
wide variety of operating conditions. Prior to delivery, your You will have been given the names of the relevant service
machine was inspected both at the Factory and by your contacts at your Distributor when the machine was
Distributor to ensure that it reaches you in optimum installed.
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as To get the most from your Distributor please help them to
specified in this Manual, are carried out by an approved satisfy you by:
JCB Distributor at the recommended intervals.
1 Giving your name, address and telephone number.
This section of the Manual gives full details of the service
requirements necessary to maintain your JCB machine at 2 Quoting your machine model and serial number.
peak efficiency.
3 Date of purchase and hours of work.
It can be seen from the Service Schedules on the following
pages that many essential service checks should only be 4 Nature of the problem.
carried out by a JCB trained specialist. Only JCB
Distributor Service Engineers have been trained by JCB to Remember, only your JCB Distributor has access to the
carry out such specialist tasks, and only JCB Distributor vast resources available at JCB to help support you. In
Service Engineers are equipped with the necessary addition, your Distributor is able to offer a variety of
special tools and test equipment to perform such tasks, programmes covering Warranty, Fixed Price Servicing,
thoroughly, safely, accurately and efficiently. Safety Inspections, including weight tests, covering both
legal and insurance requirements.
JCB regularly updates its Distributors advising them of any
product developments, changes in specifications and Service/Maintenance Agreements
procedures. Therefore only a JCB Distributor is fully able
to maintain and service your machine. To help plan and spread the costs of maintaining your
machine, we strongly recommend you take advantage of
A Service Record Sheet or Book is provided which will the many Service and Maintenance Agreements your
enable you to plan your service requirements and keep a Distributor can offer. These can be tailor made to meet
service history record. It should be dated, signed and your operating conditions, work schedule etc.
stamped by your Distributor each time your machine is
serviced. Please consult your JCB Distributor for details.

Remember, if your machine has been correctly

maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.

Owner/Operator Support
JCB together with your Distributor wants you to be
completely satisfied with your new JCB machine. If you do

3-117 9803/4160-14 3-117

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Service Schedules

Service Schedules

Introduction How to Use the Service Schedules

T3-012_3

A badly maintained machine is a danger to the operator In the example shown, A shows all service requirements to
and the people working around him. Make sure that the be carried out every 10 hours and B shows the
regular maintenance and lubrication jobs listed in the requirements to be carried out every 500 hours.
service schedules are done to keep the machine in a safe
and efficient working condition. Important: Services should be carried out at either the
hourly interval or calendar interval, whichever occurs first.
!MWARNING Refer to Calendar Equivalents.

Maintenance must be done only by suitably qualified

and competent persons. Before doing any
maintenance make sure the machine is safe. It should
be correctly parked on firm level ground.

To prevent anyone starting the engine, remove the

starter key. Disconnect the battery and block the
wheels when you are working beneath the machine.

If you do not take these precautions you could be

killed or injured.
9-3-1-1

Apart from the daily jobs, the schedules are based on

machine running hours. Keep a regular check on the
hourmeter readings to correctly gauge service intervals.
Do not use a machine which is due for a service. Make
sure any defects found during the regular maintenance
checks are rectified immediately. 795390-1

Calendar equivalents:
Every 10 Hours = Daily
Every 50 Hours = Weekly
Every 100 Hours = Monthly
Every 500 Hours = Six Months
Every 1000 Hours = 1 Yearl
Every 2000 Hours = 2 Years
Every 5000 Hours = 5 Years

Note: Services should be carried out at either the hourly

interval or calendar interval, whichever occurs first.

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 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Service Schedules

Pre-start Cold Checks, Service Points and Fluid Levels

Table 17. Engine
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 500 Hr 1000 Hr 2000 Hr
Hr
Oil Level and Condition Check

Oil and Filter Change (1)

Coolant Change

Coolant Level Check

Coolant strength and Condition Check

Air Cleaner Dust Valve Clean(2)

Air Cleaner Outer Element Change (3)
Air Cleaner Inner Element Change

Fuel System For Leaks and Check

Contamination
Fuel Filter Drain

Fuel Filter Change

Fuel Sedimenter Check

Fan Belt Tension/Condition Check

Fan Belt Change

Valve Clearances Check/Adjust

External Oil Leaks Check

(1) In arduous conditions change the oil and filter after every 250 Hours or three months (whichever comes first).
(2) Clean more often when working in dusty environments
(3) Change outer element more frequently in dusty operating environments.

3-119 9803/4160-14 3-119

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Service Schedules
Table 18. Transmission and Axles
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Transmission Oil Level Check

Transmission Strainer/Filter Change

Differential Oil Level Check

Differential Oil Change

Hub Oil Check

Hub Oil Change

Axle Breathers Clean

Tyre Pressures/Condition Check

Wheel Nut Security Check

Axle Mount Security Check

Driveshaft Security Check

Bevel Ring Gear Deflection Check

Plunger
Driveshaft and Universal Joints Grease

Table 19. Hydraulics

Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Oil Level Check

Oil Filter Change

Oil Change
and
Sample
Servo Filter Change

Tank Filler Cap Change

Tank Suction Strainers (2 off) Clean

Hoses, Rams and Pipework for Check

Damage or Leaks

Table 20. Brakes

Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Parkbrake Operation Check

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 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Service Schedules
Table 21. Electrics
Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Instrument Panel Operation Check

Battery Electrolyte Level (if applicable) Check

Battery Charge and Condition Check

Battery Terminals for Condition & Check

Tightness
Wiring for Chaffing and Routing Check

Table 22. Bodywork and Cab

Pre-start Cold Checks, Service Operation Daily Weekly Monthly First 6 Monthly Yearly 2 Yearly
Points and Fluid Levels 10 Hr 50 Hr 100 Hr 100 Hr 500 Hr 1000 Hr 2000 Hr
Machine Condition Generally Check
Wing Mirrors Condition & Security Check

All Pivot Pins Grease

Driveshaft Joints Grease(1)

Window Washer Fluid Level Fill

Cab Heater Intake Filter(s) Clean(2)

Seat Belt Condition and Security Check

ROPS/FOPS Structure Check

(1) Grease more frequently when operating in arduous conditions.

(2) Clean more frequently in dusty operating environments.

3-121 9803/4160-14 3-121

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Service Schedules

Functional Test and Final Inspection

Functional Test and and Final Inspection Operation 10 100 250 As 500 1000 2000
Hr(1) Hr(2) Hr and Hr Hr Hr
When
ENGINE
Idle Speed - Check and Adjust

Torque Converter Stall Speed - Check

Combined Stall Speed - Check

Max. No Load Speed - Check and Adjust

Throttle System and Control Cable - Check

Operation of Stop Control/E.S.O.S. - Check

Exhaust Smoke - Check

Fuel System For Leaks and Contamination - Check

Exhaust System Security - Check

Air Inlet System Security - Check

Coolant System for Leaks - Check

TRANSMISSION AND AXLES

Clutch Pack Pressures - Check

Clutch Disconnect/Dump Button - Check

Clutch Pack Calibration - Check

Speed Change and Selection - Check

Forward/Reverse Selection/Operation - Check

Neutral Start Operation - Check

Reverse Alarm (if fitted) - Check

Oil Cooler and Pipework - Check

HYDRAULICS
MRV Pressure - Check and Adjust

Steer Circuit MRV Pressure - Check and Adjust

ARV Pressure - Check and Adjust

Operation of All Services - Check

Hoses for Damage and Leaks - Check

Pipework for Damage and Leaks - Check

Piston Rods and Gland Seals - Check

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 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Service Schedules

Functional Test and and Final Inspection Operation 10 100 250 As 500 1000 2000
Hr(1) Hr(2) Hr and Hr Hr Hr
When
ELECTRICS
Starter Motor - Check

Alternator - Check

Gauges and Warning Lights - Check

Proximity Sensor Function - Check

Cab Switches - Check

Wiper Motors - Check

Heater - Check

Other (give details) - Check

CAB
Glazing for Correct Fit - Check

Doors and Hinges - Check

Tool Kit and Handbook - Check

Locks and Keys - Check

Seat/Seat Belts - Check

PAINTWORK
Condition - Check

ATTACHMENTS
Attachment Circuit Pressures - Check

Operation - Check

REGISTRATION/CERTIFICATION
Form 2530 (F91) (UK Requirement) - Lift - Check

Form 2531 (F96/F97) (UK Requirement) - Check

SWL Stickers (UK) - Renew as

Required

(1) Operations must be carried out at the end of each set period, ie. The 10 Hour operations must be carried out after every
10 hours.
(2) 100 Hour operations marked with a symbol are carried out at the Initial 100 Hour Service ONLY.

Table 23. Key

Regular Maintenance Check
Initial 100 Hour Check Only

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 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Lubricants and Capacities

Lubricants and Capacities

Note: New engines DO NOT require a running-in period. engine is gently run-in. Under no circumstances should the
The engine/machine should be used in a normal work engine be allowed to idle for extended periods; (e.g.
cycle immediately; glazing of the piston cylinder bores, warming up without load).
resulting in excessive oil consumption, could occur if the

Table 24. 426 and 436 Machines

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
SPECIFICATION
Engine Oil
-10 to 50° C (1) 17.5 litres (3.9 UK gal) JCB Extreme Performance Engine ACEA E3/B3/A3 API CH-4A3
Oil 15W/40
Gearbox 426 27 litres (5.9 UK gal)(2) JCB HP Universal ATF ZF TE-ML 06, 11, 12, 14
436 32.5 litres (7.1 UK gal)(2) JCB HP Universal ATF ZF TE-ML 06, 11, 12, 14
Axles 426 39 litres (8.6 UK gal) JCB LS Gear Oil API GL4, MIL-L-2105B(3)
Front
426 37 litres (8.1 UK gal) JCB LS Gear Oil API GL4, MIL-L-2105B(3)
Rear
436 39 litres (8.6 UK gal) JCB LS Gear Oil API GL4, MIL-L-2105B(3)
Each
Hydraulic System 210 litres (46.2 UK gal)(4) JCB HP Hydraulic Fluid ISO VG46
Cooling System 35 litres (7.7 UK gal) JCB Antifreeze and Inhibitor ASTM D6210
( Coolant Mixtures ( 3-124))
Fuel System 230 litres (50.6 UK gal) Diesel Oil ( Types of ASTM D975-66T Nos. 1D,
Fuel ( 3-79)) 2D.
Grease Points JCB HP Grease(5) Lithium based
Autolube System (if JCB MPL EP Grease Lithium based
fitted)

(1) If API CH-4 or ACEA E3/B3/A3 engine oil is not available, then the engine oil must be changed every 250 hours.
(2) The figure quoted is TOTAL system capacity. Use the 'MAX' and 'MIN' marks on the dipstick when refilling the system.
(3) Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
(4) The total hydraulic system capacity depends on the equipment being used. Fill the system with all rams closed and
watch the level indicator.
(5) If JCB Special MPL Grease is used for normal greasing, all 100 hour greasing operations must be carried out at TEN
(10) HOUR intervals.

Note: Biodegradeable Hydraulic Fluid is a factory option Replace the coolant mixture according to the intervals
ONLY. Replenish with JCB Biodegradeable Multigrade shown in the machine's Service Schedule.
Hydraulic fluid. For further information, contact Wheeled
Loader Technical Service.
!MWARNING
Coolant Mixtures Antifreeze can be harmful. Obey the manufacturer's
T3-009_3 instructions when handling full strength or diluted
Check the strength of the coolant mixture at least once a antifreeze.
year, preferably at the start of the cold period. 7-3-4-4_1

3-124 9803/4160-14 3-124

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Lubricants and Capacities
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.

50% Concentration (Standard)

Protects against damage down to -40 °C (-39 °F)

60% Concentration (Extreme Conditions Only)

Protects against damage down to -56 °C (-68 °F)

Important: Do not exceed a 60% concentration, as the

freezing protection provided reduces beyond this point.

If you use any other brand of antifreeze:

– Ensure that the antifreeze complies with International

Specification ASTM D6210.
– Always read and understand the manufacturer's
instructions.
– Ensure that a corrosion inhibitor is included. Serious
damage to the cooling system can occur if corrosion
inhibitors are not used.
– Ensure that the antifreeze is ethylene glycol based
and does not use Organic Acid Technology (OAT).

3-125 9803/4160-14 3-125

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Cleaning the Machine

Cleaning the Machine

Clean the machine using water and/or steam. Pay

particular attention to the underside. Do not allow mud to
build up on the engine or transmission. Make sure the
radiator grille is not clogged up.

It is important to note that excessive power washine can

cause damage to the seals and bearings. Take care during
routine machine washing not to direct high pressure water
jets directly at oil seals or universal joints.

Note: The machine should always be greased after

pressure washing or steam cleaning.

Avoid using neat detergent - always dilute detergents as

per the manufacturer's recommendations, otherwise
damage to the paint finish may occur.

Rinse off all the detergent with water.

3-126 9803/4160-14 3-126

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Checking for Damage

Checking for Damage

T3-013

1 Inspect steelwork for damage. Note damaged

paintwork for future repair.

2 Make sure all pivot pins are correctly in place and

secured by their locking devices.

3 Ensure that the steps and handrails are undamaged

and secure.

4 Check for broken or cracked window glass. Replace

damaged items.

5 Check all bucket teeth for damage and security.

6 Check all lamp lenses for damage.

7 Inspect the tyres for damage and penetration by

sharp objects.

8 Check that all safety decals are in place and

undamaged. Fit new decals where necessary.

3-127 9803/4160-14 3-127

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Checking the ROPS/FOPS Structure

Checking the ROPS/FOPS Structure

1 Check the structure for damage.

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

are in place and are undamaged.

3 Make sure that the ROPS/FOPS mounting bolts A are

tightened to the correct torque setting. This should be
270 Nm (199 lbf ft).


 

Fig 97.

3-128 9803/4160-14 3-128

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Articulation Lock

Articulation Lock

Installing the Articulation Lock Removing the Articulation Lock

The articulation lock is stowed in the machine's toolbox. 1 Remove locking pins A and B.
The articulation lock is fitted with the machine in the
`straight ahead' position. 2 Stow locking bar C in the tool box.

1 Steer the machine to bring the front and rear wheels

in a straight line.

2 Apply the park brake, put the transmission in neutral

and stop the engine.

3 Remove articulation lock bar C from the tool box.

4 Position articulation lock bar. Fit pins A and B into the

articulation lock positions as shown. If the pins do not
fit, fit pin A, turn the steering wheel slightly to align
hole for pin B.

Fig 98.

3-129 9803/4160-14 3-129

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Loader Arm Safety strut

Loader Arm Safety strut

Installing the Safety Strut

1 Empty the shovel and raise the loader arm enough to
fit safety strut A.

2 Apply the park brake, put the transmission in neutral

and stop the engine.

3 Fit the Strut:

a Remove the strut from its stowage position.

b Place the strut around the ram.

c Secure the strut into position using strap B.

4 Start the engine.

5 Slowly lower the loader arm onto the safety strut. Stop Fig 99.
the movement immediately the weight of the arm is
supported by the strut.

Note: Extreme care must be taken when lowering the

loader arm onto the safety strut. 'Feather' the lever to lower
the loader arm slowly.

Removing the Safety Strut

1 Make sure the park brake is engaged and that the
transmission is in neutral.

2 Raise the loader arm to take the weight off safety strut
A. Stop the engine.

3 Remove the strut:

a Release securing strap B.

b Remove safety strut A.

c Return the safety strut to its stowage position.

3-130 9803/4160-14 3-130

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Greasing

Greasing

For interval Service Schedules 426 from M1231500, Shovel Pivot Pins (HT)
436 from M1305000 ( 3-10)
Total of 6 grease points. (1 to 6)
The machine must be greased regularly to keep it working
efficiently. Regular greasing will also increase the
Loader Arm Pivot Points (HT)
machine's working life.
Total of 18 grease points (7 to 24)
Grease should be applied with a grease gun, normally two
strokes of the gun should be sufficient. Stop the greasing
procedure when fresh grease appears at the joint. Use the
recommended grease, Lubricants and Capacities -        
426 from M1231500 ( 3-21). 

In the following illustrations, the grease points are 
numbered. Count off the grease points as you apply 
grease to each one. Refit the dust caps after greasing. 

 
Note: In arduous conditions the shovel pivot pins should  
be greased at least every ten (10) hours.   
 



Fig 100.

Shovel Pivot Pins (ZX)

Total of 4 grease points. (1 to 4)

Loader Arm Pivot Points (ZX)

Total of 9 grease points (5 to 13)

 
 



 
 


Fig 101.

3-131 9803/4160-14 3-131

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Greasing

Centre Pivot Steer Rams

Total of 3 grease points Total of 4 grease points (6 to 9)

Fig 103.
Fig 102.

Rear Axle Pivots

Total of 2 grease points (4 and 5)

3-132 9803/4160-14 3-132

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Greasing

Propshafts
Total of 7 grease points

    

 

Fig 104.

3-133 9803/4160-14 3-133

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Automatic Greasing System

Automatic Greasing System

When the ignition is ON, the greasing system performs all

operations automatically.

Grease Points
 

The following points are greased by the automatic system

(when fitted):

1 Shovel Pivot Pins

2 Loader Arm Pivot Points

3 Centre Pivot and Steering Rams

Note: All other grease points must continue to be greased

as per the Service Schedules

Filling the Reservoir

It is essential that the correct grease is used in this system.
Lubricants and Capacities - 426 from
M1231500 ( 3-21) 

1 Remove the dust cap from the filler coupling A.

2 Carefully clean the area around the filler coupling and

the coupling on the filler hose.
Fig 105.
3 Attach the filler hose to the coupling A.

4 Fill the reservoir C until the top of the follower plate D

(the plate on top of the grease) is level with the
maximum level mark.

5 Remove the filler hose, clean the coupling and refit

the dust cap.

Note: Any air introduced during filling will exit via the
reservoir vent. If large amounts of air are present, carry out
a continuous greasing cycle for one minute.

3-134 9803/4160-14 3-134

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Automatic Greasing System

Testing the System Replacing the Fill Point Filter

In order to test the correct operation of the system, carry 1 Clean the area around the filler coupling A.
out a single greasing cycle.
2 Remove the filler coupling A from the filter F.
Single Greasing Cycle
3 Loosen locknut E.
1 Turn starter switch to IGN.
4 Remove filter F.
2 Press test button 105-B for 3 to 5 seconds.
Note: Grease may flow from the housing when the filter is
3 The system will perform a single cycle test. removed.

In order to prime the system after cleaning the machine or 5 Screw the new filter into the filter housing, hand-tight
to vent the system; a continuous should be carried out. only, until the O ring contacts the filter housing.

Continouous Greasing Cycle 6 Tighten locknut E to 15Nm (133lbf in).

1 Turn starter switch to IGN. 7 Refit the filler coupling.

2 Press test button B for more than 6 seconds.

3 The system will perform a continuous cycle run.

Note: The continuous greasing cycle will continue to run

until the starter switch is turned to OFF.

Fig 106.

3-135 9803/4160-14 3-135

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Automatic Greasing System

System Controls

Item Indication Description

A Yellow Lamp Low Level Reservoir requires replenishing.
B Red Lamp Error System not operating due to insufficient grease.
C Green Lamp Light Duty Long interval between grease cycles.
Greasing Mode
D Green Lamp Normal Duty Standard interval between grease cycles.
Greasing Mode
E Green Lamp Heavy Duty Short interval between grease cycles.
Greasing Cycle
F Greasing Mode Selection Switch - Press the mode switch repeatedly until the
desired mode lamp (C, D or E) illuminates.









Fig 107.

Note: When switched on, the system will default to Normal

Duty Mode. For normal operation, this is the required
mode. When working in arduous conditions, Heavy Duty
Mode should be selected.

3-136 9803/4160-14 3-136

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Access Panels

Access Panels

Engine Covers Rear Grille

Opening and Closing the Engine Covers Opening the Rear Grille

Opening the Engine Covers 1 Apply the park brake, put the transmission in neutral
and stop the engine.
1 Apply the park brake, put the transmission in neutral
and stop the engine. 2 Open the left side engine cover Engine
Covers ( 3-28) and unlatch the rear grille by pulling
2 Pull handle 4D. It is recommended that the panels are the release catch A.
kept locked.
3 Open the rear grille by pulling the bottom of the grille
3 Pull handle 4E out and up, allow the gas-strut to open out and up, the grille will be lifted by the gas struts.
the panel.
Closing the Rear Grille
Closing the Engine Covers
1 Close the rear grille by pulling the bottom of the grille
1 Pull handle 4E down and inwards. down against the pressure of the gas struts. Keep a
firm hold on the grille.
2 Make sure the panel is latched.
2 Make sure the rear grille is latched. Close and lock
the engine cover.

Fig 108.

Fig 109.

3-137 9803/4160-14 3-137

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Access Panels

Heater Door
Opening the Heater Door

1 Apply the park brake, put the transmission in neutral

and stop the engine.

2 Unlock and press catch A.

Closing the Heater Door

1 Close the heater door by pushing on the area

surrounding the catch.

2 Make sure the heater door is latched. It is

recommended that the door is kept locked.

Fig 110.

3-138 9803/4160-14 3-138

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Heating and Ventilation

Heating and Ventilation

Air Conditioning
Adjusting the Compressor Belt

Note: The engine illustrated is the type fitted to early

machines. The engine on later machines looks different
but the procedure is not affected.

1 Park the machine on level ground.

2 Apply the park brake, put the transmission in neutral

and stop the engine.

3 Open the right side engine panel.

4 Loosen pivot bolt 58A (Not shown). Loosen bolts 58B

and 58C.

5 Adjust the belt by positioning the compressor to give

5 mm (3/16 in) slack at the mid point of the longest
run.

6 Tighten bolts 58B and 58C. Tighten pivot bolt 58A.

7 Close and lock the engine panel.

Fig 111.

3-139 9803/4160-14 3-139

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Heating and Ventilation

Cab Heater Filters

Cleaning the Intake Filter

1 Park the machine on level ground. Engage the park

brake. Put the transmission in neutral. Lower the
attachments to the ground. Stop the engine. Remove
the starter key.

2 To gain access to the cab heater air filter 92A, open

heater door Opening the Heater Door ( 3-30).

3 Open fasteners at 92B, remove cover 92C.

4 Remove filter A and shake out the loose dust and

clean using low pressure compressed air. Renew the
filter if damaged.

Note: An additional filter D may be fitted behind filter A, if

applicable, remove filter D by pulling tag provided. Fig 113.
Magnetic strips hold the filter in place. Refit the filter
making sure it is located correctly. Renew the filter if
damaged.

5 Refit filter A, close heater door.



Fig 112.

3-140 9803/4160-14 3-140

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Electrical System

Electrical System

Battery
Note: Before commencing work on the battery you must
read Battery ( 3-141) in Health and Safety.

Checking the Electrolyte Level

Maintenance free batteries used in normal temperate

climate applications should not need topping up. However,
in certain conditions (such as prolonged operation at
tropical temperatures or if the alternator overcharges) the
electrolyte level should be checked as described below.

!MCAUTION
Do not disconnect the alternator, the battery, or any
part of the charging circuit with the engine running. Fig 114.
8-3-4-1

!MWARNING
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.
5-2-2-4

1 Park the machine on firm level ground, engage the

park brake and set the transmission to neutral.

2 Remove the battery cell covers and check the

electrolyte level in each cell. The electrolyte should
be 6 mm (0.25 in) above the plates.

!MWARNING
Do not top the battery up with acid. The electrolyte
could boil out and burn you.
2-3-4-6

3 Top-up if necessary with distilled water or de-ionised

water.

4 Check the Connections. Make sure that the terminals

are tight and clean. Coat them with petroleum jelly to
prevent corrosion.

3-141 9803/4160-14 3-141

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Electrical System

Jump Starting The Engine 1 The park brake should have been engaged when the
machine was last parked. If it is not engaged, engage
it now.
!MWARNING
Do not use a battery if its electrolyte is frozen. To 2 Set all switches in the cab to off.
prevent the battery electrolyte from freezing, keep the
battery fully charged. 3 Lower the shovel to the ground, if it is not already
there. It will lower itself under its own weight when you
Do not try to charge a frozen battery or jump-start and operate the lever. Operate the lever carefully to
run the engine, the battery could explode. control the rate of descent. If your machine is fitted
with hose burst protection valves you will not be able
Batteries produce a flammable gas, which is to lower the shovel. In this case install the safety strut.
explosive; do not smoke when checking the
electrolyte levels. 4 Connect the positive booster cable to the positive (+)
terminal on the machine battery. Connect the other
When jump-starting from another vehicle, make sure end of this cable to the positive (+) terminal of the
that the two vehicles do not touch each other. This booster supply.
prevents any chance of sparks near the battery.
5 Connect the negative (-) booster cable to a suitable
Set all the machine switches to their OFF positions point on the engine.
before connecting the external power supply. Even
with the starter switch set to off some circuits will be Note: A good frame earth is part of the main frame, free
energised when the external power supply is from paint and dirt. Do not use a pivot pin for an earth.
connected.
6 Connect the other end of this cable to the negative (-
Do not connect the booster (slave) supply directly ) terminal of the booster supply.
across the starter motor. Doing this by-passes the
neutral gear safety switch. If the machine is in gear, it 7 Start the engine.
may 'runaway' and kill or injure bystanders.

Use only sound jump leads with securely attached

!MWARNING
connectors. Connect one jump lead at a time. When the engine is running, there are rotating parts in
the engine compartment. Before disconnecting the
The machine has a negative earth electrical system. cables, make sure that you have no loose clothing
Check which battery terminal is positive (+) before (cuffs, ties etc.) which could get caught in rotating
making any connections. parts.
2-2-4-3
Keep metal watch straps and jewellery away from the
jump lead connectors and the battery terminals - an 8 Disconnect the negative booster cable from the
accidental short could cause serious burns and engine. Then disconnect it from the booster supply.
damage equipment.
9 Disconnect the positive booster cable from the
Make sure you know the voltage of the machine. The positive (+) terminal on the battery. Then disconnect
booster (slave) supply must not be higher than that of it from the booster supply.
the machine. Using a higher voltage supply will
damage your machine's electrical system.

If you do not know the voltage of your booster (slave)

supply, then contact your JCB dealer for advice. Do
not attempt to jump-start the engine until you are sure
of the voltage of the booster (slave) supply.
4-2-2-3_1

3-142 9803/4160-14 3-142

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Electrical System

Fuses and Relays Fuse Circuit(s) Protected Rating

C1 Starter Relay 3A
!MCAUTION C2 Cigar Lighter (24 volt) 10A
Fuses Loader Auxiliaries, Quickhitch, Servo
Always replace fuses with ones of correct ampere C3 7.5A
Isolator
rating to avoid electrical system damage.
C4 Rear Wash/Wipe 7.5A
8-3-3-5
C5 Front Wash/Wipe, Horn 10A
The electrical circuits are protected by fuses. The fuses are C6 Heater Motor 20A
located in a fuse box (shown with the lid removed) behind
the drivers seat. C7 Air Conditioning Compressor 5A
C8 Heated Mirrors/Seat, Suspension Seat 20A
If a fuse ruptures, find out why and rectify the fault before C9 Direction Indicators 5A
fitting a new one.
C10 Trailer Electrics (12 volt) 10A
Secondary Fuses
Fuse Circuit(s) Protected Rating
Fuse Circuit(s) Protected Rating D1 EMS Ignition Feed 3A
A1 Front Work Lights Relay, Ign 1 Relay 20A ZF Computer Ignition Feed, SRS
D2 7.5A
A2 Additional Front Work Lights (2 Total) 10A Solenoid
A3 Rear Work Lights (2 Total) 10A D3 Reversing Camera 5A
A4 Additional Rear Work Lights (2 Total) 10A D4 Emergency Steer System 1A
A5 Roadlight Switch (Headlights) 15A D5 Shutdown relay, Immobiliser 5A
A6 Main Beam 10A D6 Reverse Alarm and Lights 5A
A7 Rear Fog Light 5A 24/12 volt Dropper (Radio, Cigar /
D7 10A
Lighter, Auxiliary)
A8 Grid Heater Relay 3A
D8 Reverse Fan 5A
A9 Blank -
D9 Brakelights, Tow Hitch Solenoids 7.5A
A10 Blank -
D10 Shovel and Arm Reset 7.5A

Fuse Circuit(s) Protected Rating

B1 RH Sidelights 3A
B2 LH Sidelights 3A
B3 Heated Rear Screen 15A
B4 EMS Battery Feed 3A
B5 ZF Computer Battery Feed 7.5A
B6 Hazard Indicators 10A
B7 Beacon/Interior Light 7.5A
B8 Radio (24 volt) 10A
B9 Headlight Flash 15A
B10 Ignition Relays/Roadlight Illumination 5A

3-143 9803/4160-14 3-143

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Electrical System
Relays
 
Relay Circuit
1 Ignition 1
2 Ignition 2
3 Brake Lights
4 Reverse Light
 
5 Engine Shutdown
6 Transmission Reverse
7 Emergency Steer
  
8 Air Conditioning
9 Transmission Dump
   
10 Ignition 3
11 Front Work Lights
12 Lights  
 
13 Flasher Unit
14 Heated Rear Screen
15 Neutral Start    
16 Blank
17 Blank

Diagnostic Connectors

X ZF Transmission
Y EMS

Fig 115.

3-144 9803/4160-14 3-144

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Electrical System
Primary Fuses Fuse Circuit(s) Protected Rating

The primary fuses are located in a fuse box mounted at the PF5 Rear Work Lights 40A
right side of the battery bay inside the rear grille. Roadlight Switch (Headlights)

If a fuse ruptures, find out why and rectify the fault before
fitting a new one. Fuse Circuit(s) Protected Rating
PF6 Heater Motor 60A
Fuse Circuit(s) Protected Rating Air Conditioning Compressor
PF1 Front Work Lights 60A
Ignition 1 Fuse Circuit(s) Protected Rating
EMS (Ignition Feed) PF7 RH Sidelights 30A
ZF Computer (Ignition Feed) LH Sidelights
ACCS Heated Rear Screen
Reversing Camera EMS (Battery Feed)
Emergency Steer System ZF Computer (Battery Feed)
ESOS and Immobiliser
Reverse Alarm and Lights Fuse Circuit(s) Protected Rating
Blank PF8 Engine ECU 30A

Fuse Circuit(s) Protected Rating


PF2 Hazard Indicators 40A  
Beacon and Interior Light  
Radio (24 volt)
Headlight Flash 
 

Fuse Circuit(s) Protected Rating  

PF3 Ignition 60A
Fig 116.
Roadlight Illumination

Fuse Circuit(s) Protected Rating

PF4 Cigar Lighter 60A
Loader Auxiliaries, Quickhitch and
Servo Isolator
Rear Wash/Wipe
Front Wash/Wipe and Horn
24/12 volt Dropper (Radio, Cigar Lighter
and Aux.)
Reverse Fan
Brake Lights and Tow Hitch Solenoids
Shovel and Arm Reset

3-145 9803/4160-14 3-145

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Engine

Engine

Checking the Oil Level

1 Park the machine on level ground and lower the
attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the right side engine cover.

4 Check that the oil level is between the two marks on

the dipstick 34B.

5 If necessary, add the recommended oil through the

filler point 34A, Lubricants and Capacities - 426
from M1231500 ( 3-21).

6 Make sure the filler cap and the dipstick are secure.
Close and lock the engine cover.

Fig 117.

3-146 9803/4160-14 3-146

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Engine

Changing the Oil and Filter

1 Park the machine on level ground and lower the
attachments to the ground.

2 Stop the engine. Put the transmission in neutral and

remove the starter key.

3 Open the left side engine cover.

4 Place a suitable container beneath the drain plug

118A (to catch the oil).

5 Remove drain plug and its 'O' ring and drain the oil
from the sump. Renew the 'O' ring.

6 Clean and refit the drain plug and its 'O' ring and
tighten the drain plug to 34 Nm (25 lbf ft). DO NOT
OVERTIGHTEN.

7 Clean the area around the filter head. Unscrew the

filter canister 120C. Remember that it will be full of oil.

Fig 118.

8 Clean filter head 120D. Make sure that the `O' ring is
removed.

9 Add clean engine oil to the new filter canister. Allow

time for the oil to pass through the filter element.

10 Smear the seal 120E on the new filter canister with

clean engine oil.

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

filter head.

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

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

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

3-147 9803/4160-14 3-147

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Engine
14 Make sure the engine will not start and turn the Cooling System
engine using the starter key until the oil pressure
warning light is extinguished. Checking the Coolant Level
Note: To make sure the engine will not start, remove the 1 Park the machine on level ground. Engage the park
engine shut-off solenoid fuse Fuses and brake. Put the transmission in neutral. Stop the
Relays ( 3-44). engine and let it cool down. Open the rightside engine
cover.
15 Refit the engine shut-off solenoid fuse and start the
engine. Check for leaks. When the engine has 2 Check that the coolant is visible in the header tank
cooled, check the oil level. 50A. The level should be between 1/3 and 2/3 full. If
not, continue with steps 3 to 5.

3 Close the engine cover. Top up the coolant system

through the filler cap. Access to the filler cap is
through a hole in the engine cover above the filler
cap.

4 Refit the filler cap and make sure it is tight.

Fig 119. 5 Run the engine for a while to raise the coolant to
working temperature and pressure. Stop the engine
and check for leaks.

Fig 121.
Fig 120.
Draining and Refilling the Coolant

1 Park the machine on level ground. Engage the park

brake. Put the transmission in neutral. Stop the
engine and let it cool down. Open the left side engine
cover.

2 Access to the filler cap is through a hole in the engine

cover above the filler cap. Carefully loosen cap. Let
any pressure escape. Remove the cap.

3-148 9803/4160-14 3-148

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Engine
3 Remove drain plug from the radiator drain extension
and drain the coolant.

4 Flush the system using clean water.

5 Refit drain plug.

6 Prepare a mixture of water and sodium carbonate.

Note: Use 1.0 lb (0.5 kg) of sodium carbonate for every 23

litre (5.0 UKGal).

7 Fill the system slowly with the mixture to prevent air

locks. Wait 2 to 3 minutes to allow air to be vented and
top up the header tank to 1/3 full. Do not fit the filler
cap at this stage.

8 Run the engine for 5 minutes at the normal running

temperature. Stop the engine and allow to cool.

9 Drain the cooling system, checking that the coolant is

not dirty. If it is, repeat the flushing process (steps 6 to
9).

10 Refill the system as described at step 7 but using pre-

mixed water/antifreeze solution (as specified in
Coolant Mixtures ( 3-124)). Do not overfill. Fit
the filler cap.

Note: A 50% antifreeze mixture must be used even if frost

protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.

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

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

Note: Make sure the heater control is in the hot position

before running the engine. This will ensure that the coolant
mixture circulates through the entire cooling system.

Anti-Corrosion Additives

To provide sufficient corrosion protection, supplemental

coolant additive (SCA) must be added to the coolant
mixture. The coolant filter provides the required amount of
SCA, provided the filter is replaced at regular intervals.

3-149 9803/4160-14 3-149

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Engine

Air Filter 4 Release latches 122A and remove cover 122B.

Gently remove the outer element 122C by moving the
Changing the Elements end up and down or by twisting to disengage the seal.
Take care not to tap or knock the element as you
Note: In a dusty working environment, the outer element remove it. If necessary, remove the inner element
may have to be renewed more frequently than the service 122D.
schedule recommendation. A new inner element must be
fitted at latest every third time the outer element is 5 Clean inside canister 122E, particularly the outlet
changed. As a reminder, mark the inner element with a felt tube on which the elements seal. Clean dust valve
tip pen each time you change only the outer element. DO 122F.
NOT attempt to wash or clean elements - they must be
renewed. 6 Check the new elements before fitting, discard if
damaged. Smear the seals 122G and 122H with
1 Apply the park brake, put the transmission in neutral engine oil or preferably, silicone oil then carefully
and stop the engine. install the elements into the outlet tube. Apply firm
pressure to the outer ring of the element, not the soft
2 Open the engine cover on the right side of the centre.
machine.
7 Refit cover 122B making sure it is properly located
3 If changing the inner element, disconnect the filter then secure latches 122A. Make sure that the dust
induction hose 122J to prevent dust getting into the valve 122F is at the bottom.
engine. Cover the hose to prevent rain and dirt getting
into the engine. 8 Connect the induction hose 122J. Make sure the air
filter blocked switch connector is fitted. Check all
hoses for condition and tightness.

    

 

Fig 122.

3-150 9803/4160-14 3-150

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Engine

Engine Drive Belt

Check the Engine Drive Belt

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

1 Park the machine on level ground.

2 Apply the park brake, put the transmission in neutral

and stop the engine.

3 Open the engine cover.

4 Inspect the belt for the damage as follows:- Fig 123.

a Cracks across the belt width A are acceptable.

b Cracks across the belt which intersect those in the

direction of the belt length B are not acceptable.

c Renew the belt if it has unacceptable cracks or if

it is frayed or has pieces of material missing as at
C.

5 Check the belt tension. The maximum deflection on

the longest run of the belt as at D should be 9.5 to
12.7 mm (0.375 to 0.5 in). If the deflection is
excessive, see your JCB distributor for drive belt
replacement.

6 Close and `latch' the engine cover.

Fig 124.

3-151 9803/4160-14 3-151

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Fuel System

Fuel System

Types of Fuel – ASTM D975-91 Class 1-1DA.

T3-007_2 – JP7, MIL T38219 XF63.
Use good quality diesel fuel to get the correct power and – NATO F63.
performance from your engine.
Sulphur Content
Recommended Fuel Specification

– EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4. !MCAUTION

– BS2869 Class A2. A combination of water and sulphur will have a
– ASTM D975-91 Class 2-2DA, US DF1, US DF2, US corrosive chemical effect on fuel injection equipment.
DFA. It is essential that water is eradicated from the fuel
system when high sulphur fuels are used.
– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade
ENG-3-2
3.
High sulphur content can cause engine wear. (High
Note: Where low sulphur/low aromatic fuels are used it is
sulphur fuel is not normally found in North America,
important that lubricity additives are used. The additives
Europe or Australia.) If you have to use high sulphur fuel
listed below are advertised as being suitable for bringing
you must change the engine oil more frequently.
the lubricity levels of kerosene/low sulphur fuels up to
those of diesel fuels. They have not been tested or
Table 25.
approved by the engine manufacturer. They should be
added by your fuel supplier who should understand the Percentage of sulphur in Oil Change Interval
concentration level necessary. the fuel (%)
Less than 0.5 Normal
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), 0.5 to 1.0 0.75 of normal
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels. More than 1.0 0.50 of normal

2 Lubrizol 539N. Dosage (on Swedish low sulphur fuel) Aviation Kerosene Fuels
250 ppm.
Note: Aviation kerosene fuels are not approved and their
3 Paradyne 7505 (from Infineum). Dosage 500 ppm use may cause damage to components. Warranty will not
(0.05%). be allowed on any component where damage is found to
have been caused by the use of aviation kerosene.
!MCAUTION Low Temperature Fuels
Consult your fuel supplier or JCB distributor about the
suitability of any fuel you are unsure of. Special winter fuels may be available for engine operation
GEN-9-2 at temperatures below 0°C (32°F). These fuels have a
lower viscosity. They also limit wax formation in the fuel at
Acceptable Fuel Specification low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter.)
!MCAUTION Fatty Acid Methyl Ester Fuels as a Replacement
The fuel specification below is acceptable, however for diesel Fuels
this fuel may reduce the life of the fuel injection
equipment. The use of this fuel may also affect the Fuel resources such as Rape Methyl Ester and Soybean
engine performance. Methyl ester, collectively known as Fatty Acid Methyl
GEN-9-3

3-152 9803/4160-14 3-152

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Fuel System
Esters are being used as alternatives and extenders for Draining the Fuel Filter
mineral oil.
1 Apply the park brake, put the transmission in neutral
Fatty Acid Methyl Esters must conform to certain and stop the engine.
standards to be of acceptable quality, just as mineral oils
do at present. 2 Open the engine cover.

Consult your JCB distributor for advice about the use of 3 Drain off any water in the bowl 125B by turning valve
Fatty Acid Methyl Ester fuels, as improper application may 125A 4 turns anti-clockwise until the valve drops
impair engine performance. down 25 mm (1.0 in).

!MWARNING 4 Push up valve and turn clockwise until closed. Do not

over tighten.
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from 5 Close and lock the engine cover.
the fuel system. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. There could be a fire and injury if you
do not follow these precautions.
INT-3-2-2_1

Petrol

!MWARNING
Petrol
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6

Filling the Tank

At the end of every working day, fill the tank with the correct
type of fuel. This will prevent overnight condensation from
developing in the fuel.

The cap incorporates a side mounted barrel lock that is

operated by the ignition/door key. Once the key has been
removed, the cap will simply rotate on the filler neck. To
remove the cap from the filler neck, the key must be Fig 125.
reinserted and the cap unlocked.

3-153 9803/4160-14 3-153

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Fuel System

Changing the Suction Side Fuel Filter Changing the Pressure Side Fuel Filter
Element Element
1 Apply the park brake, put the transmission in neutral 1 Apply the park brake, put the transmission in neutral
and stop the engine. and stop the engine.

2 Open the engine cover. 2 Open the engine cover.

3 Disconnect the `Water in Fuel' sensor connector C. 3 Unscrew the filter element B, the element is hand
Disconnect the fuel heater connector (if fitted). tight but may require a strap wrench to remove. The
filter will be full of fuel.
4 Unscrew the filter element A, the element is hand
tight but may require a strap wrench to remove. The 4 DO NOT fill the filter element with fuel before fitting.
filter will be full of fuel. Install filter element, hand tight only.

5 To assist with priming, fill the filter element with fuel 5 Close and lock the engine cover.
before fitting. Install filter element, hand tight only.
Check for leaks.

6 Reconnect connector(s) mentioned in step 3.

7 Close and lock the engine cover.

Fig 127.

Important: This engine fuel system is self-priming, do not

attempt to bleed the fuel system manually.

Fig 126.

3-154 9803/4160-14 3-154

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Fuel System

Priming the Fuel System

Priming the fuel system is required only after changing the
fuel filter elements:

1 Apply the park brake, put the transmission in neutral

and stop the engine.

2 Make sure that there is enough fuel in the fuel tank.

3 Release priming handle A by turning it counter-

clockwise.

Fig 128.

4 Pump priming handle until pressure has built up in the

system.

5 Lock priming handle A by pushing back into the filter

housing and turning clockwise until secure.

6 Start the engine. Slowly increase the engine speed

while any remaining air is vented from the system.

3-155 9803/4160-14 3-155

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Hydraulic System

Hydraulic System

Checking the Fluid Level

1 Apply the park brake, put the transmission in neutral,
lower the shovel/attachment to the ground. Make
sure it is flat on the ground. Stop the engine.

2 The level should be visible in the sight glass 75A.

3 If necessary, top up with hydraulic fluid.

4 Open the right side engine cover. Open filler cap 76B.

5 Top up the system with hydraulic fluid, Lubricants

and Capacities - 426 from M1231500 ( 3-21).

6 Refit filler cap 76B. Make sure it is secure. Close the

engine cover.

Fig 129.

Fig 130.

3-156 9803/4160-14 3-156

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Hydraulic System

Changing the Filter Element

1 Open the right side top step.

2 Remove hydraulic tank cap.

3 Unscrew and remove nuts 77C, cover plate 77D and

seal 77E.

4 Pull out the complete element assembly 77F and the

seal.

5 Remove the nut and spring 77K. Remove the filter

element 77L from the spindle and clean magnets 77J.

6 Fit the new element 77L and the new seals 77G and
77H.

7 Replace the cover plate 77D and tighten nuts 77C to

7 Nm (5 lbf ft).

8 Top up the system with hydraulic fluid, Lubricants

and Capacities - 426 from M1231500 ( 3-21).

9 Refit filler cap. Make sure it is secure. Close the right

side top step.

 






Fig 131.

3-157 9803/4160-14 3-157

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Transmission

Transmission

Checking the Oil Level (Engine Running)

Note: The transmission oil level should be checked only
when the oil is at the correct working temperature.

1 Park the machine on level ground.

2 Apply the park brake, put the transmission in neutral.

3 Open the left side engine cover. Remove, wipe and

replace the dipstick 81A.

Note: Turn `T' handle 81D, two full turns anti-clockwise to

release the dipstick. Turn `T' handle 81D, two full turns
clockwise to fasten in position. Check that the dipstick is
secure.

4 Make sure the oil is at the correct mark on the

dipstick.

5 If necessary, add recommended oil at dipstick/filler

point 81A.

Note: The transmission may overheat if the oil level is

above the HOT mark.

6 Close and lock the engine cover.

Fig 132.

3-158 9803/4160-14 3-158

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Transmission

Changing the Oil and Filter Checking the Differential Oil Level
1 Place a suitable container beneath the transmission. 1 Clean the area around fill/level plug 134A.
(To catch the oil).
2 Remove fill/level plug 134A and its seal, oil should be
2 Remove the dipstick 81A and drain plug 133B. level with the bottom of the hole.

3 Drain the oil. Clean and refit drain plug 133B. 3 Top up with the recommended oil if necessary.

4 Unscrew and discard old filter 133C. Clean the 4 Clean and refit fill/level plug 134A and its seal.
mounting face and lubricate the seal on the new filter Tighten to 85 Nm (60 lbf ft).
with clean torque converter fluid.

5 Fit the new filter 133C hand tight only.

6 Fill the system with new oil at dipstick/filler point 81A.

Note: Do not fill past the top mark on the dipstick.

Fig 134.

Draining and Refilling the Differential Oil

1 Clean the area around fill/level plug 134A.

2 Remove fill/level plug 134A and its seal.

3 Place a suitable container beneath the drain plug

 134B (to catch the oil).

4 Remove drain plug 134B. Allow the oil to drain fully.

5 Clean and refit drain plug 134B and its seal. Plug
134B is magnetic, make sure all debris is removed.
Tighten to 85 Nm (60 lbf ft).

Fig 133. 6 Fill the axle with the recommended oil through fill/
level plug 134A.

7 Clean and refit fill/level plug 134A and its seal.

Tighten to 85 Nm (60 lbf ft).

3-159 9803/4160-14 3-159

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Transmission

Checking the Hub Oil Level Draining and Refilling the Hub Oil
1 Make sure the OIL LEVEL mark on the hub is 1 Make sure fill/drain plug 135A is at the bottom, as
horizontal, as shown at 135B. shown at 135C.

2 Clean the area around fill/drain plug 135A. 2 Clean the area around fill/drain plug 135A.

3 Remove fill/drain plug 135A and its seal, oil should be 3 Remove fill/drain plug 135A and its seal, drain the oil
level with the bottom of the hole. into a suitable container. Allow the oil to drain fully.

4 Top up with the recommended oil if necessary. 4 Drive the machine slowly forward to bring the OIL
LEVEL mark on the hubs into the horizontal position,
5 Clean and refit fill/drain plug 135A and its seal. as shown at 135B. Fill the hub with the
Tighten to 85 Nm (60 lbf ft). recommended oil through fill/drain plug 135A until oil
starts to dribble out.
Note: The hubs must be treated separately, a total of four
hubs. 5 Clean and refit fill/drain plug 135A and its seal.
Tighten to 85 Nm (60 lbf ft).

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

hubs.



Fig 135.

3-160 9803/4160-14 3-160

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Wheels and Tyres

Wheels and Tyres

Tyre Inflation b Inflate the tyre to the recommended pressure. Do

T3-010_2
not over-inflate.
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.

!MWARNING
An exploding tyre can kill. Inflated tyres can explode if
over-heated or over-inflated. Follow the instructions
given when inflating the tyres. Do not cut or weld the
rims. Use a tyre/wheel specialist for all repair work.
2-3-2-7_2

!MWARNING
Wheels and tyres are heavy. Take care when lifting or
moving them. Fig 136.

Store with care to ensure that they cannot fall and Checking the Wheel Nut Torques
cause injury.
13-3-1-7_1 On new machines, and whenever a wheel has been
removed, check the wheel nut torques every 10 hours until
1 Prepare the wheel. they stay correct.

Before you add air to the tyre, make sure it is correctly Every day, before starting work, check that the wheel nuts
fitted on the machine or installed in a tyre inflation are tight.
cage. Fig 136. ( 3-161).
The correct torque is shown in Table 26. Torque
2 Prepare the equipment. Settings - Front and Rear ( 3-161).

a Use only an air supply system which includes a Table 26. Torque Settings - Front and Rear
pressure regulator. Set the regulator no higher Nm lbf ft
than 1.38 bar (20 psi) above the recommended
600 443
tyre pressure. For recommended tyres and
pressures for your machine, see Tyre Sizes and
Pressures.

b Use an air hose fitted with a self-locking air chuck

and remote shut-off valve.

3 Add the air.

a Make sure that the air hose is correctly connected

to the tyre valve. Clear other people from the area.
Stand behind the tread of the tyre while adding the
air.

3-161 9803/4160-14 3-161

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Window Washers

Window Washers

Replenishing

Fig 137.

To gain access to the washer bottle A, open the heater

compartment door. Opening the Heater Door ( 3-30)
The washer bottle is located inside.

Fill the windscreen washer bottle with a suitable liquid.

The liquid should contain a de-icing fluid to prevent it
freezing. Do not use engine coolant antifreeze.

On completion, close and lock the access cover.

3-162 9803/4160-14 3-162

 Section 3 - Routine Maintenance
Routine Maintenance (426 from Ser. No. 1295000, 436 from Ser. No. 1410000)
Window Washers

Page left intentionally blank

3-163 9803/4160-14 3-163

Section A

Attachments
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-12



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section A - Attachments

Page left intentionally blank

A-0 9803/4160-12 A-0

 Section A - Attachments

Contents Page No.

Optional Attachments
Quick Release Couplings ....................................................................... A - 1
Connecting and Disconnecting .......................................................... A - 1

A-i A-i
 Section A - Attachments

Contents Page No.

A - ii A - ii
 Section A - Attachments

Optional Attachments
Quick Release Couplings
T4-001

Connecting and Disconnecting wedge underneath the sleeve and destroy the
coupling.
Flat face quick release couplings allow the operator to – Don't damage the faces of the couplings - this can
remove and install attachments swiftly and efficiently. prevent connection and disconnection, or damage
Generally, your machine pipework will have female seals and cause leakage.
couplings A fitted, and the optional attachment hoses will – Don't try to dismantle the couplings - they are non
have male couplings B fitted. Fig 1. ( A-2). serviceable parts. If a coupling is damaged it should
be replaced with a new one.
The quick release couplings should be trouble free and
relatively easy to connect and disconnect, provided they
are kept clean and used correctly. The recommendations !MWARNING
listed below should always apply when using flat face Hydraulic fluid at pressure can injure you. Make the
quick release couplings. machine safe before connecting or disconnecting
quick release couplings; stop the engine and then
Finally, please read the correct fitting and releasing operate the attachment control a few times to vent
procedures before installing or removing any optional residual hydraulic pressure in the attachment hoses.
attachment fitted with quick release couplings.
2-4-1-11

Quick Release Couplings - Do's and Don'ts

!MWARNING
– Do wipe the two faces of the coupling and make sure The external surfaces of the couplings must be clean
they are clean before connecting. before connecting or disconnecting. Ingress of dirt
– Do make sure the outside sleeve (female coupling) is will cause fluid leaks and difficulty in connecting or
pulled back when disconnecting. disconnecting. You could be killed or seriously injured
– Do connect and disconnect a new coupling two or by faulty Quick Release Couplings.
three times to 'work' the PTFE seals - sometimes a 2-4-1-15
new coupling will stick if the seals have not been
'worked'. Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service hose line
– Do use a spanner on the hexagon flats of the coupling
must be vented. Make sure the hose service line has been
when fitting adaptors.
vented before connecting or removing hoses.
– Do use a rubber or hide hammer to disconnect a
coupling if it sticks - sticking may occur if there is dirt
present in the coupling.
– Don't attempt to re-connect a damaged half coupling
- this will destroy the seals and necessitate replacing
both half couplings.
– Don't leave the coupling where it may be run over by
a machine or otherwise crushed - this will distort the
coupling sleeve and prevent correct connection and
disconnection.
– Don't clamp on the smooth diameter of the coupling
when fitting adaptors - always use the hexagon.
– Don't try to turn the sleeve (female coupling) when the
coupling has been disconnected - the locking ball will

A-1 9803/4160-12 A-1

 Section A - Attachments
Optional Attachments
Quick Release Couplings
Connecting Quick Release Couplings

1 Remove any residual hydraulic pressure trapped in

the service line hose.

2 Wipe the two faces of the male and female couplings

and make sure they are clean.

3 Make sure that ball 1-C in the female coupling is

located in one of its slots.

4 Fit the male coupling into the female coupling; To

ensure that the coupling is not accidentally released,
rotate sleeve 1-E half a turn and make sure that the
locking ball 1-C does not align with the slot 1-D.

Disconnecting Quick Release Couplings

1 Remove any residual hydraulic pressure trapped in

the service line hose.

2 Align the slot 1-D with ball 1-C.

3 Pull back sleeve 1-E to release the coupling.

Fig 1.

A-2 9803/4160-12 A-2

Section B

Body and Framework

Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-12



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section B - Body and Framework

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B-0 9803/4160-12 B-0

 Section B - Body and Framework

Contents Page No.

Technical Data
Air Conditioning Option ........................................................................... B - 1

Basic Operation
Air Conditioning ...................................................................................... B-3
R134a Refrigerant ............................................................................. B-4
System Operation .............................................................................. B-4
System Control .................................................................................. B-7
Safety Procedures ............................................................................. B-7

Fault Finding
Air Conditioning ...................................................................................... B - 9
Visual Inspection ............................................................................... B - 9
System Diagnosis ............................................................................ B - 17

Service Procedures
Rivet Nuts ............................................................................................. B - 27
Fitting Procedure ............................................................................. B - 28
Air Conditioning .................................................................................... B - 29
Checking Refrigerant Charge Level ................................................ B - 29
Leak Testing .................................................................................... B - 30
Tightening Leaking Hoses ............................................................... B - 30
Refrigerant Charging and Discharging ............................................ B - 31
Pressure Switch Assembly (Two Switch System) ........................... B - 36
Binary Pressure Switch Testing (Single Switch System) ................. B - 37
Condenser ....................................................................................... B - 38

Air Conditioning
Early Type ............................................................................................ B - 39
The Air Conditioning Unit ................................................................ B - 39
The Blower Unit ............................................................................... B - 42
Thermostat ...................................................................................... B - 42
Evaporator ....................................................................................... B - 42
Pressure Switches ........................................................................... B - 44
Later Type ............................................................................................ B - 45
The Air Conditioning Unit ................................................................ B - 45
The Blower Motor ............................................................................ B - 49
Thermostat ...................................................................................... B - 49
Evaporator ....................................................................................... B - 49
Air Conditioning - 426 from M532100, 436 from M533700 ................... B - 51
426 from M1231500, 436 from M1305000 ........................................... B - 52
The Air Conditioning Unit ................................................................ B - 52
Filters ............................................................................................... B - 55
Blower Motor ................................................................................... B - 56
Thermostat ...................................................................................... B - 58
Evaporator ....................................................................................... B - 59
Expansion Valve .............................................................................. B - 61
Heater Radiator ............................................................................... B - 62
Binary Pressure Switch ................................................................... B - 64

Cab
Glazing ................................................................................................. B - 65
Direct Glazing .................................................................................. B - 65

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

Contents Page No.

ROP/FOPS Structure ........................................................................... B - 71
426 prior to M1231500, 436 prior to M1305000 .............................. B - 71
426 from M1231500, 436 from M1305000 ...................................... B - 72

Bodywork
Removal and Replacement of the Rear Bodywork ............................... B - 73
Removal .......................................................................................... B - 73
Replacement ................................................................................... B - 77

Centre Pivot
Removal and Replacement .................................................................. B - 79
Removal .......................................................................................... B - 79
Replacement ................................................................................... B - 81

Cooling Pack
426 from Serial No. 532500 ................................................................. B - 84
Removal and Replacement (426 from Serial No. 532500) .............. B - 85
Dismantling and Assembly .............................................................. B - 90
436 from Serial No. 534200 .................................................................. B - 91
Removal and Replacement ............................................................. B - 92
Dismantling and Assembly .............................................................. B - 95
426 from M1231500, 436 from M1305000 .......................................... B - 97
Introduction ...................................................................................... B - 97
Removal .......................................................................................... B - 97

B - ii B - ii
 Section B - Body & Framework

Technical Data
Air Conditioning Option

Binary Switch Settings

Low pressure 2.05 bar (29.8 lbf/ in. 2.1Kg/cm)
High pressure 23.5 bar (341 lbf/ in, 24Kg/cm)
Thermostatic Switch Settings
Cut out 32.0°F to 34.0°F (0°C to 1.1°C)
Cut in 44.0°F to 46.0°F (6.6°C to 7.7°C)
Refrigerant
426 machines to S/N 532099, 436 machines to S/N 533699
1.6 Kg of R134a Gas (P12 thin condenser)
2.0 Kg of R134a Gas (thick condenser)
426 machines from S/N 532100, 436 machines from S/N 533700
1.3 Kg of R134a Gas
Oil
Type Pag oil
Quantity
Recharge the system 1.5 fluid oz. (42.6 millilitres)
Component replacement
Condenser 2.0 fluid oz (56.8 millilitres)
Evaporator 3.0 fluid oz. (85.2 millilitres)
Hoses 2 to 4 fluid oz. (56.8 to 113.6 millilitres)
Receiver Drier 2.0 fluid oz. (56.8 millilitres)
Compressor None - pre charged

B-1 9803/4160-12 B-1

 Section B - Body & Framework
Technical Data
Air Conditioning Option

Fig 1. Typical Thick Condenser

Fig 2. Typical Thin Condenser

B-2 9803/4160-12 B-2

 Section B - Body & Framework
Basic Operation
Air Conditioning

Basic Operation
Air Conditioning

Fig 1.

B-3 9803/4160-12 B-3

 Section B - Body & Framework
Basic Operation
Air Conditioning

R134a Refrigerant
TB-006

Refrigerants are the basic ingredient of all air conditioning

systems and are used to transfer the heat energy around
the system. Refrigerant type R134a is used in the air
conditioning system. It's full chemical name is:

1, 1, 1, 2-Tetraflouroethane (CH2FCF2)

R134a is a HFC (HydrFlouroCarbon) and is non-toxic,

non-flammable and non-explosive at normal atmospheric
temperature and pressure. It can be flammable under
certain pressure and air mixtures.

Due to environmental concerns, the use of ozone

depleting chlorofluorocarbons (CFCs) in the air
conditioning systems is being gradually phased out. The
R-12 refrigerant used in some systems contains CFCs. Air
conditioning systems using R-134a refrigerant are not
compatible with systems using R-12 refrigerant. No
attempt should be made to charge R-134a systems with R-
12 refrigerant.

Important: Refer to the safety procedures within this

section before handling refrigerants.
Fig 2.
Good installation practice is required to avoid the release
of refrigerant into the atmosphere. Refrigerant R134a The major components of the system are the compressor
contains no chlorine and has an Ozone Depleting Potential 1A, condenser 1B, receiver drier 1C, expansion valve 1D
(ODP) of zero, and a Global Warming Potential (GWP) of and evaporator coil 1E.
0.1.
To operate the air conditioning, press switch 3F to switch
System Operation the system on. Press switch 3G to operate the two speed
heater fan. Rotate 3H to select the desired temperature.
To maintain optimum operator comfort in warm climates or Control 3J enables the operator to select either
during seasons of high ambient temperature, the air recirculating air or fresh air from outside the machine. A
conditioning system delivers cool, dehumidified air into the combination of both is also obtainable. For later machines
cab. Cooling is provided by passing the warm ambient air, refer to the end of this section.
together with recirculated air, over an evaporator coil in the
air conditioning unit. Air conditioning system power is generated from the
engine, via an electromagnetic clutch to the compressor.
The air conditioning system is a closed circuit through Three switches, connected in series, are included in the
which the refrigerant is circulated, its state changing from clutch supply line, all must be closed for the clutch and
gas to liquid and back to gas again, as it is forced through therefore the air conditioning system to operate.
the system.
The compressor 1A draws in low pressure refrigerant gas
from the suction line (evaporator to compressor) and
increases refrigerant pressure through compression. This
process also increases the refrigerant temperature.

High pressure refrigerant is forced from the compressor to

the condenser 1B, which is mounted at the rear of the
engine. Ambient air is drawn across the condenser by the

B-4 9803/4160-12 B-4

 Section B - Body & Framework
Basic Operation
Air Conditioning
engine driven cooling fan. In the condenser, the refrigerant Cool de-humidified air is emitted through air vents into the
changes state to a high pressure, warm liquid. cab.

The refrigerant passes through the receiver drier 1C, The low temperature, low pressure, high heat content
which contains a desiccant to remove moisture from the refrigerant gas, is now drawn by suction back to the
system. compressor, where the cycle is completed.

The receiver drier serves as a reservoir for refrigerant and To start the air conditioning press switch 3F. (‘AC’ switch
also includes a filter to remove foreign particles from the located in the roof panel)
system
1 Air Recirculation

Turn to the left to recirculated air in the cab. Turn to

the right for fresh air from outside.

The control can be adjusted to give a combination of

recirculated and fresh air.

Note: In dusty conditions, it is recommended that air be

recirculated within the cab, otherwise the filter may
become clogged.

2 Temperature

Turn to the right to increase the heat.

3 Fan

Turn to switch on the cab three-speed heater fan.

Turn further for faster speeds. It functions only with
the starter switch on.

Three air vents 4B are located on the cab pillars, a further

three air vents 4C are located on the console and one air
Fig 3. vent 4D is located low down on the side console. The vents
can be turned to direct the air flow where required. When
The warm temperature, high pressure refrigerant is forced the vents are open, hot or cold air will flow directly into the
by compressor action into the expansion valve 1D, which cab. More fixed air vents are located in the panel below the
meters the amount of refrigerant entering the evaporator. rear window.
In the expansion valve the refrigerant instantaneously
expands to become a low pressure, low temperature For the most effective front window demisting, the air vents
liquid. should be closed and air circulation control turned fully to
the left
The refrigerant is drawn through the evaporator coil 1E by
the suction of the compressor. The temperature of
refrigerant is now considerably below that of the air being
drawn across the evaporator coil by the blowers. Heat is
transferred from the ambient and recirculated air to the
refrigerant, causing the low pressure liquid to vaporise and
become a low pressure gas. Moisture in the air condenses
on the evaporator coil and is drained away via condensate.

B-5 9803/4160-12 B-5

 Section B - Body & Framework
Basic Operation
Air Conditioning

Fig 4.

B-6 9803/4160-12 B-6

 Section B - Body & Framework
Basic Operation
Air Conditioning

System Control adhered to by all personnel servicing the air conditioning

system.
Control of the system is achieved by the cyclic action of the
compressor's electromagnetic clutch. When current is fed
to the field coil of the compressor's clutch, a magnetic field
!MWARNING
develops between the field coil and the armature which The air conditioning system is a closed loop system
pulls the field coil, complete with clutch assembly, onto the and contains pressurised refrigerant. No part of the
compressor's rotor. Since the clutch assembly is turned system should be disconnected until the system has
constantly by the crankshaft pulley drive belt, the been discharged by a refrigeration engineer or a
compressor armature turns, starting the refrigeration cycle. suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Current is fed to the field coil through three series switches 4-3-4-1_2
whose contacts are controlled by the following:

1 The manual switch 3F in the cab

!MCAUTION
Do not operate the air conditioning system when there
2 The thermostat switch monitoring the evaporator is no refrigerant in the system, otherwise the
temperature compressor will be damaged.
4-3-4-4
3 The high and low level pressure switches
1 It is critical that the correct refrigerant (R-134a) is
Switch 3F will start the refrigeration cycle provided that the used and that charging is done only by qualified
ambient temperature in the cab is greater than 0°C and the personnel. As a precaution, in case of accidental
refrigerant pressure remains within the specified limits. leakage, discharging and charging of the vehicle
refrigerant system must be conducted in a well
The thermostat has its sensor inserted in the evaporator ventilated area.
coil. It controls the refrigeration cycle by switching the
compressor clutch on and off to prevent freezing of the 2 Containers of refrigerant should be stored in a cool
condensate on the evaporator coil. environment away from direct sunlight.

The pressure level switches are housed in a common

assembly located adjacent to the Receiver Drier. If the
!MWARNING
refrigerant pressure exceeds the upper pressure limit Do not carry out welding operations close to the air
specified or falls below the lower limit, the contacts will conditioning refrigerant circuit. A poisonous gas is
open and the clutch will disengage, closing down the produced when refrigerant comes into contact with
refrigeration cycle. naked flames. Do not smoke or allow naked flames
close to the refrigerant circuit.
Pressures Switch Settings BF-1-9

High Pressure Switch 23 bar (341 lbf/ in2) 3 Do Not perform welding operations close to
refrigerant hoses (maintain a distance of at least 0.5m
Low Pressure Switch 2.06 bar (29.8 lbf/ in2) from hoses).

4 Do Not steam clean refrigerant system components.

Safety Procedures
5 When charging or discharging the refrigerant system
The air conditioning system includes a pressurised closed
refrain from smoking. Naked flames must not be
circuit containing a non-CFC, environmentally friendly
allowed in the immediate vicinity. The refrigerant does
refrigerant, Type R-134a. Any service procedure which
not give off a poisonous odour, however, when it
breaks into the closed circuit and therefore requires
comes into contact with a naked flame, a poisonous
discharging of the system, must only be carried out by
gas is produced.
service personnel with specialist knowledge of air
conditioning systems. The following guidelines should be

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 Section B - Body & Framework
Basic Operation
Air Conditioning
6 When handling refrigerant, rubber gloves and
goggles should be worn. Operators should ensure
that no refrigerant comes into contact with the skin.
Particular care should be taken when connecting or
disconnecting charging hoses or pressure switches.
When these components are connected to the
system, a short release of refrigerant occurs. This
results in a high velocity, very cold gas being emitted
from the connection point.

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 Section B - Body & Framework


Air Conditioning

!MWARNING 3 While inspecting the condenser, check the hose

connections. Condenser failure can be caused by
Make the machine safe before working underneath it. loose hoses. Hose movement can cause a fatigue
Park the machine on level ground and lower the failure of the condenser tubing adjacent to the fittings.
attachments, (If it is necessary to work with the loader Make sure the hoses are securely clamped.
arms raised, then the loader arm safety strut must be
fitted). See Loader Arm Safety Strut in MAINTENANCE Receiver Drier
section. Engage the parking brake, put the
transmission in neutral and stop the engine. Chock The receiver drier is located under the engine cover
both sides of all four wheels. If you are working near attached to the radiator cowl
the articulation danger zone, fit the articulation safety
lock. See Articulation Lock in MAINTENANCE section. 1 Clean the sight glass on the top housing of the
4-3-2-4_1 receiver drier.

Visual Inspection 2 Check the sight glass, in a normal operating system

the sight glass should be clear. (See Sight Glass
The following checks are visual inspection items that can Indications ( B-11).)
be carried out without the need for specialist equipment or
the need to open the air conditioning circuit. 3 Check the hose connections to the receiver drier for
signs of cracks or wear due to being insecurely
clamped. Any suspect hoses should be noted and
!MWARNING rectified only as detailed in Service
The air conditioning system is a closed loop system Procedures ( B-27). Do not attempt to remove any
and contains pressurised refrigerant. No part of the hoses from a charged air conditioning system.
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
!MWARNING
frostbitten or injured by escaping refrigerant. The air conditioning system is a closed loop system
4-3-4-1_2
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
The visual checks are to be carried out without the engine been discharged by a refrigeration engineer or a
running unless specifically stated. suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Condenser 4-3-4-1_2

The condenser is located at the rear of the machine.

1 Raise the rear grille and engine covers. Compressor and Drive Belt

2 Check that the condenser is free of leaves, debris, The compressor is mounted to a bracket secured to the
mud or built up dirt deposits. The condenser needs to engine.
be relatively clean in order to function efficiently as a
heat exchanger. If the condenser obviously needs 1 Check that the compressor is securely mounted to
cleaning refer to Condenser ( B-38). the its bracket and that the bracket is securely
mounted to the engine.

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 Section B - Body & Framework
Fault Finding
Air Conditioning
2 Check that the compressor clutch assembly and drive conditioning systems and give further fault finding and
pulley are secure. maintenance information.

3 Check that the drive belt is in good condition. The belt General Fault Indications
should not show signs of excessive wear or be frayed
and should be correctly tensioned. Frayed or badly There are several indications that may help to determine
worn belts should be replaced. Belts that are the fault area on a system not working efficiently:
obviously incorrectly tensioned should be adjusted.
(See Section 3 - Routine Maintenance - Belt
Adjustment.)

4 Check the belt run between the compressor clutch

pulley and the belts engine drive pulley. The belt run
should form a straight line parallel to the engine timing
cover.

Hoses and Fittings

1 Check all visible hoses and fitting. Look for places

where the hoses flex or are fastened, clamped,
connected, bent or pass through panels. All these
places are potential wear and damage points. Any
suspect hoses should be noted and rectified only as
detailed in Service Procedures ( B-27). Do not
attempt to remove any hoses from a charged air
conditioning system.

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

2 For any hoses that may appear to require tightening

See Tightening Leaking Hoses ( B-30). (see
above Warning.)

The system will not function in very low ambient

temperatures, therefore tests should be carried out in a
warm environment.

It is recommended that, to locate faults on the system

accurately and quickly, an electronic leak detector and a
refrigerant pressure gauge should be used. However,
leaks can be detected on the system by using soapy water
applied to the suspected leak area and system pressure
can be assessed by the state of refrigerant passing
through the receiver drier sight glass. Following sections of
the manual deal with the major components of the air

B - 10 9803/4160-12 B - 10
 Section B - Body & Framework
Fault Finding
Air Conditioning

a) Poor performance. Low system pressure - Evacuate and recharge system.

Condenser matrix air flow restricted - Remove debris from around matrix using
compressed air or low pressure water.
Air filter blocked - Remove and replace.
Compressor drive belt too slack - Adjust to correct tension.

b) Warm or slightly cool air Expansion valve stuck open or closed - Renew expansion valve.
emitted from unit.

c) Blower operates on fan Blower resistor failed - Renew resistor.

speed 3 only.
Blower motor failed - Renew complete blower unit.
Blower does not operate. Fuse blown - Replace fuse and retest.

d) Compressor clutch Condenser matrix blockage - Remove debris from around matrix/renew
continually cuts out. condenser.
Overcharging of refrigerant system - Evacuate and recharge system.
Blocked expansion valve/condenser - Clear blocked component.

Sight Glass Indications glass when the compressor is running. Refer also to
Checking Refrigerant Charge Level ( B-29).
An approximate indication of the condition of the
refrigerant can be seen through the receiver/drier sight

Clear - No fault indicated unless the system is unable to provide cool air. The indication then is that the
system is completely discharged of refrigerant.

Foam or bubbles - Refrigerant low and in need of charging. (Some slight bubbling is to be expected
when R134a refrigerant is used.)

Clouded - Desiccant breakdown in the receiver-drier.

Note: Sight glass indications cannot always give a positive

identification of a problem. Further diagnosis, preferably by
a refrigeration engineer using pressure gauges, is
advisable before reaching a definite conclusion.

B - 11 9803/4160-12 B - 11
 Section B - Body & Framework
Fault Finding
Air Conditioning
No Air Conditioning

CHECK ACTION
1 Are the controls set correctly, i.e. air conditioning YES: Check 2
selected, thermostat switch set to coldest position
and blower switched on?
NO: Reset controls and retest.
2 Is the air conditioning (evaporator) blower working? YES: Check 3.
NO: Check 4.
3 Is the compressor running (visual check of pulley/ YES: Check 9.
clutch)?
NO: Check 5.
4 Is the air conditioning fuse(s) blown? YES: Renew fuse(s) and retest.
NO: Check 8.
5 Is there a 12V supply to the pressure switch YES: Check 6.
harness?
Refer to Pressure Switch Assembly (Two NO: Check 7.
Switch System) ( B-36)
6 Does the compressor clutch engage with pressure YES: Replace pressure switch assembly.
switch assembly bypassed?
Refer to Pressure Switch Assembly (Two NO: Renew the compressor clutch and retest.
Switch System) ( B-36)
7 Does the clutch engage with thermostat switch YES: Renew thermostat switch and retest.
bypassed?
NO: Check all electrical connections.
8 Are blower switch and wiring OK? YES: Renew blower unit complete.
NO: Renew switch or wiring.
9 Is sight glass indication OK? YES: Check 10.
NO: Charge check required by refrigeration engineer or
suitably trained person.
10 Is condenser air flow blocked? YES: Clean condenser and radiator.
NO: Check 11.
11 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.
NO: Call in refrigeration engineer or suitably trained
person.

B - 12 9803/4160-12 B - 12
 Section B - Body & Framework
Fault Finding
Air Conditioning
Harness Wires Table 1. Key
1 Fuse, 15A (position 6A)
Use the illustration below to complete continuity checks on 2 Connector SM
the air conditioning system and heater harness wires.
3 Heater Switch
4 Resistor
5 Connector SN
6 Heater Blower
7 Fuse, 10A (position 7B)
8 Connector TN
9 Air Conditioning ON/OFF Switch
10 Connector TP
11 Thermostat Switch
12 Interface Connector TF/RL
13 Connector TJ
14 Pressure Switch
15 Compressor Field Coil

Table 2. Zones
A Side Console Harness
B Rear Chassis Harness

Fig 1.

Fig 2.

B - 13 9803/4160-12 B - 13
 Section B - Body & Framework
Fault Finding
Air Conditioning
     Table 4. Fuses
 6C Heater Blower and Cigar Lighter
7B Air Conditioning
Table 3. Key
48 Heater Relay
Note: For fuse ratings see Section C - Electrics.
49 Heater Switch
50 Heater Blower
51 Cigar Lighter
52 Air Conditioning Compressor Clutch
53 Air conditioning Pressure Switch
54 Air Conditioning Temperature Switch
55 Air Conditioning Switch

Fig 3.

B - 14 9803/4160-12 B - 14
 Section B - Body & Framework
Fault Finding
Air Conditioning
Main Components Note:      

1 Battery
2 Isolator $13 To EMS A34
17 Starter Solenoids $14 Indicators
18 Starter Motor $15 To EMS A24
19 Start Relay $16 To EMS B4
20 Starter Switch
21 Not Applicable Lamps
22 Start-up dump Solenoid
23 Thermostart Resistor 136 Road Light Switch Illumination
24 Thermostart
25 Not Applicable Fuses
26 Dump Relay
A7 Blank
27 Heater Speed Switch
A8 Thermostart
28 Heater Blower
A9 Dump Relay
29 Air Conditioning Switch
A10 Ignition Relays
30 Air Conditioning Temperature Switch
C1 Starter Relay Solenoid
31 Air Conditioning Pressure Switch
C6 Heated Seat/Mirrors and Air Suspension Seat
32 Air Conditioning Compressor
(Option)
32A Air Conditioning Relay
C7 Air Conditioning (Option)
33 Heated Mirror Switch
C8 Heater Blower
34 Heated Mirrors
C9 Direction Indicators
35 Heated Seat Switch
C10 Heated Rear Screen
36 Seat Heating Elements
P3 Starter Solenoid
37 Air Suspension Switch
Thermostart
38 Air Suspension Compressor
Heater Blower
39 Heated Rear Screen Switch
Air Conditioning
40 Heated Rear Screen Relay
Direction Indicators
41 Heated Rear Screen
Heated Seat, Mirrors and Air Suspension Seat
42 Lights Relay Solenoid
Heated Rear Screen
43 Ignition Relay Solenoid 1
Ignition Relays
44 Ignition Relay Solenoid 2
45 Ignition Relay Solenoid 3 Note: for Fuse ratings, see Section C - Electrics.

B - 15 9803/4160-12 B - 15
 Section B - Body & Framework
Fault Finding
Air Conditioning

Fig 4.

B - 16 9803/4160-12 B - 16
 Section B - Body & Framework
Fault Finding
Air Conditioning

System Diagnosis
Normally Functioning A/C System

Gauge Readings:

Low Side Gauge - Normal.

High Side Gauge - Normal.

Other symptoms:

Sight Glass - Clear.

Discharge Air - Cold.

Normal gauge readings will depend on system

components and ambient conditions, make sure that the
valves are closed and the readings are stable and that the
system has a full charge.

The pressures on the manifold at 25 °C with the engine at

1500 RPM, the blower on maximum and the thermostat set
to maximum, should be approximately:

Typically, the high pressure is 6 - 8 times the low pressure.

LOW SIDE - 2.0 bar (2.0 kgf/cm2)(29 lbf/in2)

HIGH SIDE - 14.8 bar (15.1 kgf/cm2)(215 lbf/in2)

B - 17 9803/4160-12 B - 17
 Section B - Body & Framework
Fault Finding
Air Conditioning

Fig 5.

B - 18 9803/4160-12 B - 18
 Section B - Body & Framework
Fault Finding
Air Conditioning
Low R-134a Charge

Gauge Readings:

Low Side Gauge - Low.

High Side Gauge - Low.

Other symptoms:

Sight Glass - Bubbles continuously visible.

Diagnosis:

System slightly low on R-134a, due to leak or incorrect

charge.

Correction:

1 Leak test system.

2 Evacuate A/C system.

3 Repair system leaks.

4 Charge system with R-134a.

5 Operate system and check performance.

Fig 6.

B - 19 9803/4160-12 B - 19
 Section B - Body & Framework
Fault Finding
Air Conditioning
Poor Refrigerant Circulation

Gauge Readings:

Low Side Gauge - Zero to negative.

High Side Gauge - Low.

Other symptoms:

Receiver-Drier - Frost on tubes from receiver-drier to

evaporator unit.

Diagnosis:

Refrigerant flow obstructed by dirt, receiver-drier clogged.

Correction:

1 Evacuate A/C system.

2 Replace receiver-drier.

3 Charge system with R-134a.

4 Operate system and check performance.

Fig 7.

B - 20 9803/4160-12 B - 20
 Section B - Body & Framework
Fault Finding
Air Conditioning
No Refrigerant Circulation

Gauge Readings:

Low Side Gauge - Zero to negative.

High Side Gauge - Low.

Other symptoms:

Receiver-Drier - Frost or moisture on tubes before and

after receiver-drier.

Diagnosis:

Refrigerant flow obstructed by dirt, moisture or gas

leakage from expansion valve heat sensing tube.

Correction:

1 Evacuate A/C system.

2 Check heat sensing tube at expansion valve. Replace

expansion valve if necessary.

3 Remove expansion valve and attempt removal of dirt.

If dirt cannot be removed, replace expansion valve.
Fig 8.
4 Replace receiver-drier.

5 Charge system with R-134a.

6 Operate system and check performance.

B - 21 9803/4160-12 B - 21
 Section B - Body & Framework
Fault Finding
Air Conditioning
Insufficient Cooling of Condenser or Refrigerant
Overcharge

Gauge Readings:

Low Side Gauge - High.

High Side Gauge - High.

Other symptoms:

Sight Glass - No bubbles visible even at lower engine

RPM.

Diagnosis:

Refrigerant overcharge, condenser cooling fins clogged

with dirt or cooling fans malfunctioning.

Correction:

1 Clean condenser cooling fins.

2 Check cooling fan operation.

3 Evacuate A/C system.

4 Charge system with R-134a.

Fig 9.
5 Operate system and check performance.

B - 22 9803/4160-12 B - 22
 Section B - Body & Framework
Fault Finding
Air Conditioning
Air in System

Gauge Readings:

Low Side Gauge - High.

High Side Gauge - High.

Other symptoms:

Sight Glass - Bubbles visible during system operation.

Pipes - Low pressure pipes are hot to the touch.

Diagnosis:

Air is present in the system, possibly from inadequate

evacuation procedure.

Correction:

1 Evacuate A/C system.

2 Check compressor oil for contamination. Check

compressor for proper oil amount. Correct if
necessary.

3 Charge system with R-134a.

Fig 10.
4 Operate system and check performance.

B - 23 9803/4160-12 B - 23
 Section B - Body & Framework
Fault Finding
Air Conditioning
Expansion Valve Improperly Mounted or Heat
Sensing Tube Defective (Opening Too Wide)

Gauge Readings:

Low Side Gauge - High.

High Side Gauge - High.

Other symptoms:

Pipes - Large amount of frost or moisture on low side

pipes.

Diagnosis:

Excessive refrigerant in low side pipes possibly from

expansion valve being opened too wide.

Correction:

1 Leak test system.

2 Evacuate A/C system.

3 Repair system leaks.

4 Charge system with R-134a.

Fig 11.
5 Operate system and check performance.

B - 24 9803/4160-12 B - 24
 Section B - Body & Framework
Fault Finding
Air Conditioning
Compressor Malfunction

Gauge Readings:

Low Side Gauge - High.

High Side Gauge - Low.

Diagnosis:

Internal compressor leak or compressor mechanically

broken.

Correction:

1 Evacuate A/C system.

2 Repair or replace compressor.

3 Charge system with R-134a.

4 Operate system and check performance.

Fig 12.

B - 25 9803/4160-12 B - 25
 Section B - Body & Framework
Fault Finding
Air Conditioning
Some Moisture in the System

Gauge Readings:

Low Side Gauge - Normal, then sometimes drops to below

zero.

High Side Gauge - Normal, then sometimes goes high.

Diagnosis:

Moisture in system freezes, temporarily stopping cycle,

normal system operation returns when ice melts.

Correction:

1 Evacuate A/C system.

2 Replace receiver-drier.

3 Remove moisture by repeatedly evacuating system.

4 Charge system with R-134a.

5 Operate system and check performance.

Fig 13.

B - 26 9803/4160-12 B - 26
 Section B - Body & Framework

Service Procedures
Rivet Nuts
TB-001_2

A 'Rivet Nut' is a one piece fastener installed 'blind' from Table 1. Specifications
one side of the machine body/framework. The rivet nut 1- Rivet Nut Rivet Nut Material Rivet Drill
A is compressed so that a section of its shank forms an Thread Outside Thickness Length Hole
'upset' against the machine body/framework, leaving a Diameter Diameter (Total) Dia.
durable thread 1-B.
M5 7 0.25 - 3.00 14.00 7.10
3.00 - 5.50 17.00
M6 9 0.50 - 3.00 16.00 9.10
3.00 - 5.50 19.00
M8 11 0.50 - 3.00 18.00 11.10
3.00 - 5.50 21.00
M10 13 1.00 - 3.50 23.00 13.10
3.50 - 6.00 26.00

Note: All dimensions in mm

Fig 1.

Rivet nuts are fitted 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 rivet nuts are available. Table 1.

Specifications ( B-27) to determine the size of rivet nut
to be used for particular applications.

If for any reason a new rivet nut requires fitting, then the
correct installation procedure must be followed. Fitting
Procedure ( B-28).

Note: In an emergency, and if no installation tool is

available, it is possible to fit a rivet nut by using a nut and
bolt the same thread diameter as the rivet nut being
installed. However, this is not the recommended method.

B - 27 9803/4160-12 B - 27
 Section B - Body & Framework
Service Procedures
Rivet Nuts

Fitting Procedure (smooth bulge) seating itself against the body/

framework 4-E.
1 Drill a hole in the machine body/framework where the
rivet nut is to be fitted. De-burr hole edges. Note: The thread of the rivet nut must not be stripped, take
care when 'upsetting' the rivet nut.
2 Screw the rivet nut onto the mandrel of the installation
tool. The bottom of the mandrel should be in line with
the bottom of the rivet nut 2-A.

Fig 4.

Fig 2. 6 Remove the installation tool.

3 Wind the body of the installation tool down the

threaded mandrel until it touches the head of the rivet
nut 3-B.

Fig 3.

4 Insert the rivet nut (assembled to the tool) into the

hole drilled in step 1.

5 Hold handle 4-C and at the same time draw the

mandrel into the installation tool by turning nut 4-D.
The rivet nut will contract in length and form an 'upset'

B - 28 9803/4160-12 B - 28
 Section B - Body & Framework
Service Procedures
Air Conditioning

Air Conditioning

Checking Refrigerant Charge Level

The pressure in the system, i.e. the refrigerant charge level
can be determined by checking the state of refrigerant at
the receiver drier sight glass. The receiver drier is mounted
beneath the right-side engine cover on a vertical bulkhead
at the rear of the engine.

If the level of charge is correct the sight glass will be clear.

If the charge is low bubbles will be seen. Bubbles may also
be an indication of inadequate cooling, due to a restriction
of air flow around the condenser coil. Recharging of the
system should be carried out by an air conditioning
engineer. Check refrigerant charge level as follows:

Note: When R143a refrigerant is used slight bubbling will

be seen at the system sight glass. This is normal for this
type of refrigerant. If the system is not providing adequate
cooling refer to Fault Finding ( B-9).

1 Park the machine on firm, level ground. Lower the

loader arms to the ground. Engage the parking brake.

2 Chock the wheels, to prevent movement.

3 Raise the right-side engine cover. Fig 5.

4 Start the engine and run at idle. Switch air

conditioning ON to circulate refrigerant.

5 Check refrigerant charge level at sight glass 5A.

B - 29 9803/4160-12 B - 29
 Section B - Body & Framework
Service Procedures
Air Conditioning

Leak Testing Tightening Leaking Hoses

TB-004

!MWARNING !MWARNING
Leak testing in Air Conditioning systems should be The air conditioning system is a closed loop system
carried out only in a well ventilated area. and contains pressurised refrigerant. No part of the
BF-1-2 system should be disconnected until the system has
been discharged by a refrigeration engineer or a
Note: The refrigerant is heavier than air and will leak suitably trained person. You can be severely
downwards from the defective component. Check in still frostbitten or injured by escaping refrigerant.
conditions but in a well ventilated area. 4-3-4-1_2

Hose or pipe connections are likely leakage points of any The refrigerant hoses have crimped ferrule end fittings.
refrigerant circuit. The hose connectors have an 'O' ring seal which
compresses when the connection is tight, creating an air
It is essential that an electronic leak detector is used to tight seal.
locate leaks accurately. However, if a leak detector is not
available, an approximate source can be found by applying Hoses are used to connect the inlets and outlets of the
soap solution to the suspect area. compressor, condenser, receiver drier and expansion
valve (the evaporator coil is connected to the expansion
To test for leaks in the high pressure side of the system i.e. valve within the air conditioning unit using rigid pipes).
from the compressor output to the expansion valve, run the
air conditioning for a few minutes then switch off the engine If leakage is detected from a hose connector, either by
and test for leakage using an electronic leak detector or means of an electronic leak detector or soapy water,
soapy water. tighten the connector up and repeat the leakage test. If
leakage is still evident, it will be necessary to discharge the
To test for leakage in the low pressure side of the system, system and renew the connector 'O' ring seal.
switch off the air conditioning and leave for a few minutes
before testing.

B - 30 9803/4160-12 B - 30
 Section B - Body & Framework
Service Procedures
Air Conditioning

Refrigerant Charging and Discharging Note: If the high pressure warning light on the `Javac' unit
TB-005
comes on, throttle back the manifold low pressure valve to
Note: The procedures for refrigerant charging and provide a restriction.
discharging must only be carried out by qualified service
personnel who have received specialist training on the air 7 The 'Javac' unit 6-E will automatically switch off when
conditioning system. a pressure balance exists between the system and
the receiver bottle. Switch off 'Javac' at main switch,
but leave the system connected. Switch on after 10
!MWARNING minutes, the 'Javac' will restart if residual pressure
The air conditioning system is a closed loop system remains.
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has 8 Close valves and remove equipment.
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

Refrigerant Recovery

The recovery process clears the system refrigerant prior to

servicing or for refrigerant renewal.

Note: Do not re-use refrigerant unless you are aware of its

purity.

Note: The JCB recommended 'Javac' unit only recovers

refrigerant as a gas. Other units can recover refrigerant as
a liquid and/or gas. Always check manufacturers
instructions before using.

1 Ensure that the engine is OFF and the starter key

removed.

2 Connect the manifold to the system as shown, with

the blue hose 6-A connected to the system low
pressure port. Do Not connect the red hose 6-B.
Make sure that both valves are closed.

3 Connect the yellow hose 6-C to the 'Javac' unit filter Fig 6. Refrigerant Recovery
6-D.

4 Connect the filter 6-D to the 'Javac' unit 6-E.

5 Connect the 'Javac' unit 6-E to an empty receiver

bottle 6-F. Weigh the bottle before and after filling to
assess system capacity.

Note: Do not fill the receiver bottle to more than 80% by

weight.

6 Switch on 'Javac' unit 6-E and open the low pressure

manifold valve.

B - 31 9803/4160-12 B - 31
 Section B - Body & Framework
Service Procedures
Air Conditioning
Evacuating (Vacuuming)

This procedure follows on from the 'Recovery' process and

is necessary to ensure proper refilling of the system with
refrigerant.

To avoid leakage in the vacuum system itself, Do not use

extensions to the yellow hose (use standard 2 metre
length).

1 Recover all refrigerant from the system.

Refrigerant Recovery ( B-31).

2 Close all valves and connect the manifold as shown.

Connect the blue hose 7-A to the system low
pressure port and the red hose 7-B to the high
pressure port.

3 Connect the yellow hose 7-C to the vacuum pump 7-

D. Fig 7. Evacuating

Note: If the Electronic Vacuum Gauge 7-E is used

connected as shown. Electronic Vacuum
Gauge ( B-33), for further information.

4 Open manifold valves.

5 Switch on the vacuum pump 7-D until 740mm (29 in)

mercury vacuum reads on both gauges.

Note: Achievable vacuum will vary with altitude. Maximum

gauge reading will be 25mm (1 in) less for every 305
metres (1000 feet) above sea level.

6 Maintain suction for approximately 30 minutes.

Note: If the vacuum falls rapidly the system is leaking.

Check all connections and reseal. If the point of leakage is
not obvious, recharge the system and test again.

7 Close valves and remove equipment.

B - 32 9803/4160-12 B - 32
 Section B - Body & Framework
Service Procedures
Air Conditioning
Electronic Vacuum Gauge
ATM/BAT Normal atmospheric pressure reading.
Battery condition.
15"/510mbar 381mm (15 in)Hg. Partial vacuum -
Vacuum system is operating.
29"/980mbar 736mm (29 in)Hg. No vacuum drawn -
Possible system leakage.
8000 8.0mm (0.31 in)Hg. Partial vacuum - If
the reading does not progress the
system may have a slow leak.
1000 1.0mm (0.039 in)Hg. Deeper vacuum.
600 0.6mm (0.023 in)Hg. Deep vacuum.
400 0.4mm (0.015 in)Hg. Deep vacuum.
200 0.2mm (0.0078 in)Hg. Deep vacuum.
25 0.025mm (0.00098 in)Hg. Pump Test.
Maximum sustainable vacuum.



Fig 8.

The CPS VG100 vacuum gauge is an electronic type using

LED's to indicate various states of vacuum. It is used in
place of or to supplement the gauge on the vacuum pump.

Before connecting into the system switch on to check that

the first LED lights to show that the battery is in good
condition.

Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).

B - 33 9803/4160-12 B - 33
 Section B - Body & Framework
Service Procedures
Air Conditioning
Relubricating

Pre-lubrication is essential after recovering system

refrigerant, vacuuming and component flushing.

The system should be evacuated to a vacuum of 740mm

(29 in) of mercury before re-lubricating.

1 Ensure that the engine is OFF and the starter key is

removed.

2 Close all valves and connect the manifold as shown,

with the blue hose 9-A connected to the oil injector 9-
E and the red hose 9-B to the system high pressure
port.

3 Connect the yellow hose 9-C to the vacuum pump 9-

D.

4 Connect the other end of the oil injector 9-E to the

system low pressure point 9-F.

5 Switch on the vacuum pump 9-D and open the high Fig 9. Relubricating
pressure side valve.

6 Unscrew the oil injector cap and add the specified

quantity of refrigerant oil.

7 When 740mm (29 in) mercury shows on the vacuum

gauge, open the oil injector valve to allow the oil into
the system.

8 If more oil is needed repeat the above procedure. The

quantity of oil should be the same as that taken out
during the 'Recovery' procedure.

Note: Use only PAG oil in R-134a systems.

B - 34 9803/4160-12 B - 34
 Section B - Body & Framework
Service Procedures
Air Conditioning
Charging

This procedure is industry recommended practice for

refilling air conditioning systems with refrigerant.

Evacuate the system beforehand to 740mm (29 in) of

mercury.

1 Close all valves and connect the manifold as shown.

Connect the blue hose 10-A to system low pressure
and the red hose 10-B to system high pressure.
Connect the yellow hose 10-C to the refrigerant
cylinder 10-D.

2 Invert single valve cylinder on the scales 10-E and

zero the scale reading

Note: Some refrigerant cylinders have separate valves for

gas and liquid. Be sure to connect to the liquid port when
following the above procedure.

Note: Refrigerant can be used either in gas or liquid form. Fig 10. Charging
If recharging with gas follow the manufacturers instructions
and recharge only via the low pressure port. Do not use
liquid refrigerant at the low pressure port.

3 Slowly open the high pressure valve and allow the

vacuum to draw-in refrigerant to the specified weight
for the system. Refer to Technical Data.

Add refrigerant until the scales 10-E indicate the

specified weight for the system or the weight obtained
when the system refrigerant was previously
recovered.

Note: To speed up the process a thermostatically

controlled thermal blanket 10-F can be used around the
replenishing cylinder.

4 Close all valves and remove the equipment.

B - 35 9803/4160-12 B - 35
 Section B - Body & Framework
Service Procedures
Air Conditioning

Pressure Switch Assembly (Two Switch

System)
The pressure switch assembly comprises a low pressure
switch designed to open at approximately 2 bar (30 lbf/in2)
and a high pressure switch designed to open at 24 bar
(342 lbf/in2)

When the refrigerant pressure is within the 2 and 24 bar

limits the switches will be closed and providing the
thermostat and on/off switches are closed, a current will be
supplied to the field coil of the clutch. Through electro-
magnetic action the field coil clutch will be pulled towards
the compressor's clutch and the refrigeration cycle will
commence.

If the fault finding table indicates that the pressure switch

assembly is defective the fault may be electrical or due to
incorrect system pressure.

Follow the procedure for checking the refrigerant charge

level ( Checking Refrigerant Charge Level ( B-29))
to isolate the fault area. If the refrigerant charge level is OK
use the following electrical test procedures.

Pressure Switch Testing

1 Switch the engine off so that the air conditioning

system cannot operate.

2 Disconnect the pressure switch harness, FS, from the

side console harness and connect an external 24V
power supply between the pressure switch harness
connector and chassis. If both pressure switches are
working correctly, and the system is at the correct
charge level, the compressor clutch will operate.

If the compressor clutch does not operate with the

external power supply, one of the pressure switches
in the assembly is faulty or the level of refrigerant
charge is insufficient to close the low pressure switch.

3 Replace the pressure switch assembly. If the clutch

still fails to operate check all electrical connections.

B - 36 9803/4160-12 B - 36
 Section B - Body & Framework
Service Procedures
Air Conditioning

Binary Pressure Switch Testing (Single

Switch System)
If the fault finding table indicates that the binary pressure
switch assembly is defective the fault may be electrical or
due to incorrect system pressure.

Before testing the binary pressure switch 11-A it is

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

1 Switch OFF the engine and remove the harness

connectors 11-B from the pressure switch 11-A.

B
A

C023830

Fig 11.

2 Connect a link wire between the two harness

connectors (effectively bypassing the pressure
switch).

3 Switch on the engine and air conditioning system. If

the system operates, one of the switches inside the
binary pressure switch assembly is faulty.

4 Renew the pressure switch assembly. If the clutch still

fails to operate, check the harness electrical wiring for
damage and open or short circuits. For details of the
electrical circuits and connections, see Electrical
Connections.

B - 37 9803/4160-12 B - 37
 Section B - Body & Framework
Service Procedures
Air Conditioning

Condenser
It is likely that over a period of time, because of the
machines working environment, the airflow around the
condenser coil will become restricted due to a build up of
airborne particles

If the build up of particles is severe, heat dissipation from

the refrigerant to the air will be significantly reduced,
resulting in poor air conditioning performance.

In extreme cases, over pressurisation of the system

occurs, causing the high pressure cut-out switch to
operate and switch off the system.

High pressure cut-out can also be caused by an internal

blockage of the condenser coil.

Condenser Coil Cleaning

Take care not to damage the condenser fins or tubes.

Damaged fins must be straightened out to ensure a good
air flow through the coil.

The condenser is located at the rear of the machine.

1 Park the machine on firm level ground. Lower the

loader arms to the ground.

2 Remove the stater key.

3 Chock both front and rear wheels

4 Swing out and raise the grille at the rear of the

machine.

5 Use compressed air or low pressure water to

backflow through the coil fins. Take care not to
damage the fins.

6 Run the air conditioning and check cooling

performance.

B - 38 9803/4160-12 B - 38
 Section B - Body & Framework

Air Conditioning
Early Type

The Air Conditioning Unit 4 Remove the bottom panel by releasing the four bolts
1C.
The air conditioning unit (a/c) contains a blower unit,
evaporator and thermostat. It is located beneath the right 5 Remove the foam filter 2D from the front of the unit.
side cab door behind a hinged louvred panel 1A.

Fig 2.

Note: On later machines, foam filter 2D has been replaced

by a filter element fitted in a mounting plate and secured by
a clamp plate with antiluce fasteners.

Fig 1. !MWARNING
Note: When removing components or hoses, retain any The air conditioning system is a closed loop system
lubricant within the component/hose and replenish the and contains pressurised refrigerant. No part of the
system with the same amount of clean lubricant (PAG Oil system should be disconnected until the system has
4007/0504). been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
Removal frostbitten or injured by escaping refrigerant.
4-3-4-1_2
Removal of the unit will require the assistance of a
refrigeration engineer or suitably trained person since the 6 Drain the refrigerant from the unit and remove all pipe
refrigerant needs to be discharged from the system. work (refrigerant and air) which will prevent the unit
from being withdrawn from the machine. Check top of
1 Disconnect the battery. unit, rear, bottom and right side.

2 Remove the bolts 1B securing the louvred panel to 7 Disconnect control cables at points 3E and 3F.
the machine body. (On later machines unlock panel).
8 Remove the screws 3G securing the a/c unit to the
3 Remove the panel from its hinges. machine and carefully withdraw the unit.

B - 39 9803/4160-12 B - 39
 Section B - Body & Framework
Air Conditioning
Early Type
9 Place the unit on a solid surface and remove the ten
screws 4H from around the top of the case.

Fig 3.

10 Remove the four screws and remove the grill (not

shown).

11 Lift the lid previously secured by screws 4H.

Note: The opportunity should be taken to examine the

external air filter 2D and the recirculating air filter 4S when
the a/c unit is removed from the machine. The filters should
be washed in warm soapy water or replaced as
appropriate.

Replacement

Replacement is the reverse of the removal procedure.

B - 40 9803/4160-12 B - 40
 Section B - Body & Framework
Air Conditioning
Early Type

Fig 4.

B - 41 9803/4160-12 B - 41
 Section B - Body & Framework
Air Conditioning
Early Type

The Blower Unit Evaporator

The blower unit 5K is located inside the air conditioning The evaporator is located in the a/c unit.
unit. The only user-serviceable part is the resistor which
determines the blower motor speed. Other faults, Removal
excluding wiring faults, necessitate the replacement of the
blower unit. 1 Disconnect the battery.

Removal 2 Remove the a/c unit from the machine as previously

described and remove the lid.
Note: Record all electrical connections prior to removal.
3 Unclip the thermostat sensor wire from the
1 Disconnect the battery. evaporator 5N and gently remove the wire from
between the fins.
2 Remove the a/c unit from the machine as previously
described and remove the lid. 4 Carefully lift the evaporator complete with expansion
valve 5R from the case, bearing in mind that a certain
3 Disconnect connector SN. amount of resistance will be met due to the adhesion
from the sealing putty.
4 Remove four screws 5L securing the blower unit to
the side of the a/c unit. Replacement

5 Carefully remove the blower unit from the a/c unit. Replacement is the reverse of the removal procedure.

Replacement is the reverse of the removal procedure.

Thermostat
The Thermostat monitors the external temperature of the
evaporator and is located in the a/c unit.

Removal

1 Disconnect the battery.

2 Remove the a/c unit from the machine as previously

described and remove the lid.

3 Unclip the sensor wire 5M from the evaporator 5N

and gently remove the wire from between the fins.

4 Remove the connector from the thermostat 5P.

Note: On later machines the thermostat 5P has been

moved to the front of the a/c unit. For further information
contact JCB Technical Services.

5 Remove the two screws securing the thermostat to

the rear of the a/c unit housing.

Replacement is the reverse of the removal procedure.

B - 42 9803/4160-12 B - 42
 Section B - Body & Framework
Air Conditioning
Early Type

Fig 5.

B - 43 9803/4160-12 B - 43
 Section B - Body & Framework
Air Conditioning
Early Type

Pressure Switches
Removal and Replacement

Important: The system must be discharged before the

pressure switch is removed

!MWARNING
Goggles and rubber gloves must be worn when
pressure switches are removed or fitted. A small
amount of refrigerant is released which can be harmful
to the skin or eyes.
BF-1-10

Removal

1 Discharge the air conditioning system, see

Refrigerant Charging and
Discharging ( B-31).

2 Disconnect the electrical connections and unscrew

the pressure switch.

Replacement

1 Screw the pressure switch into the pressure switch

port and torque tighten sufficiently to form a gas-tight
seal.

2 Reconnect the electrical connection.

3 Charge the air conditioning system (discharged

during removal). See Refrigerant Charging and
Discharging ( B-31).

4 Run the air conditioning and check the pressure

switches for leaks. If any leaks are found, tighten the
pressure switch further until the leaking stops.

B - 44 9803/4160-12 B - 44
 Section B - Body & Framework
Air Conditioning
Later Type

Later Type

The Air Conditioning Unit

The air conditioning unit (a/c) contains a blower unit;
evaporator; heater radiator; binary switch and thermostat.
It is located on the right side of the cab behind a hinged
panel 6A.

B
A437760-V2

Fig 7.

!MWARNING
The air conditioning system is a closed loop system
 and contains pressurised refrigerant. No part of the
Fig 6. system should be disconnected until the system has
been discharged by a refrigeration engineer or a
Note: When removing components or hoses, retain any suitably trained person. You can be severely
lubricant within the component/hose and replenish the frostbitten or injured by escaping refrigerant.
system with the same amount of clean lubricant (PAGOil 4-3-4-1_2
4007/0504).
4 Discharge the air conditioning system. (See
Removal Refrigerant Charging and
Discharging ( B-31)). Disconnect the high and low
Removal of the unit will require the assistance of a pressure pipes.
refrigeration engineer or suitably trained person since the
refrigerant needs to be discharged from the system. 5 Turn off the coolant hose tap and remove the coolant
pipes from the a/c unit.
1 Disconnect the battery.
6 From inside the cab remove the control knobs from
2 Open the panel 6A on the right hand side of the the air conditioning controls 8C and 8D. (They may
machine. (On later machines the lock has been need to be gently prised from the control spindles)
replaced by a lift catch.)
7 Remove the nuts securing the control cables to the
3 Remove the two bolts 7B securing the panel latch to base plate, and remove the four screws 8E securing
the air conditioning unit, and remove the latch. the base plate to the console.

B - 45 9803/4160-12 B - 45
 Section B - Body & Framework
Air Conditioning
Later Type
Filters

The filters are located inside the air conditioning unit.

Removal

1 Remove the screw 9-1 securing the wire mesh filter

housing to the main casing.

Fig 8.

8 Lower the control cables down through the aperture

in the console to rest on top of the air conditioning unit

9 Remove the screws securing the a/c unit to the

machine and carefully part withdraw the unit
complete with the control cables.

10 Disconnect the electrical multi plugs between the air

conditioning unit and the machine harness, and
carefully fully withdraw the unit from the cab.

11 Place the unit onto a solid surface or work bench.

Note: The opportunity should be taken to examine the Fig 9.

external air filter and the recirculating air filter when the alc
unit is removed from the machine. The filters should be 2 Slide the wire mesh filter 10-2 from it housing. The
washed in warm soapy water or replaced as appropriate. filter can be washed out in warm soapy water.

Replacement

Replacement is the reverse of the removal procedure but

take note of the following.

1 When refitting the unit care must be taken to allow the

condensation drain hoses to run downwards. Do not
cable tie the drain hoses so there is a uphill run.
Condensation could become trapped at this point,
leading to a build up of stagnant water.

2 When refilling the cooling system use the correct

mixture of water and anti freeze. A 50% mixture
should be used even if frost protection is not needed.
(See Section 3 - Routine Maintenance - Coolant
Mixtures) If the system is being refilled, it is important
not to exceed the recommended fill rate of 10 litres
per minute.
Fig 10.

B - 46 9803/4160-12 B - 46
 Section B - Body & Framework
Air Conditioning
Later Type
3 Slide the paper element filter 11-3 from its angled
location guides in the main casing. Shake out the
loose dust and clean using low pressure compressed
air. Renew the filter if required.

Note: Use eye protection if cleaning out the filter using low
pressure compressed air.

Replacement

Replacement of the filters is the reverse of the removal

process but note the following:

1 The guides for the paper element filter 11-3 are at an

angle of approximately 60 degrees to the front face of
the main casing.

2 The paper element filter 11-3 must be fitted the

correct way round. The step in the filter casing goes
inwards, with the steel mesh covering the paper
element facing forward. (A new filter will have the
correct orientation marked on it.)

Fig 11.

Note: Forward of the angled location guides for the paper

element filter can be found a second set of guides. (These
guides run parallel to the evaporator.) They are the
location guides for the optional carbon filter.

B - 47 9803/4160-12 B - 47
 Section B - Body & Framework
Air Conditioning
Later Type

Fig 12.

Table 1. Key
10 Expansion Valve
1 Blower Motor
11 Filter (Paper Element)
2 Water Control Valve
12 Evaporator
3 Lower Front Panel
13 Thermostat Heater Radiator
4 Filter (Wire Mesh) Housing
14 Heater Radiator
5 Filter Housing securing Screw
15 Top Cover
6 Upper Front Panel
16 Evaporator/Heater Radiator Housing
7 Filter (Wire Mesh)
17 Main Casing
8 Binary Switch
9 Recirculated Air Control Flap

B - 48 9803/4160-12 B - 48
 Section B - Body & Framework
Air Conditioning
Later Type

The Blower Motor Removal

The blower motor 12-1 is located inside the air conditioning 1 Disconnect the battery.
unit. The only user-serviceable part is the resistor which
determines the blower motor speed. Other faults, 2 Remove the bolts holding the upper front panel 12-6
excluding wiring faults, necessitate the replacement of the to the main casing
blower unit.
3 Carefully withdraw the thermostat probe 13A from the
Removal evaporator/radiator housing.

1 Disconnect the battery. 4 Remove the electrical multi plug connector from the
thermostat.
2 Remove the bolts securing the lower front panel 12-3
to the main casing. 5 Remove the two nuts and washers securing the
thermostat to the rear of the upper front panel.
3 Slowly, partially withdraw the blower unit assembly
12-1 from the main casing Replacement

4 Disconnect the electrical connections to the blower Replacement is the reverse of the removal procedure.
unit
Evaporator
5 Carefully remove the blower unit from the a/c unit.
The evaporator is located in the a/c unit.
Replacement
Removal
Replacement is the reverse of the removal procedure.
1 Disconnect the battery.

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
6 frostbitten or injured by escaping refrigerant.
A 4-3-4-1_2

3 2 Discharge the air conditioning system (See

Refrigerant Charging and
Discharging ( B-31)). Disconnect the high and low
pressure pipes.
A437760-V4
3 Turn off the coolant hose tap and remove the coolant
Fig 13. pipes from the a/c unit.

Thermostat Note: When disconnecting the coolant pipes from the a/c
unit, disconnect the inlet hose from its upper connection.
The thermostat monitors the external temperature of the This will remove the need to release the control cable, as
evaporator and is located in the a/c unit. to do so will result in damage to the cable securing clip.

B - 49 9803/4160-12 B - 49
 Section B - Body & Framework
Air Conditioning
Later Type
4 Disconnect the electrical connection 14B to the
binary switch

5 Carefully withdraw the thermostat probe 14A from the

evaporator/radiator housing.

A
Fig 15.

2 When refilling the cooling system use the correct

mixture of water and anti freeze. A 50% mixture
should be used even if frost protection is not needed.
(See Section 3 - Routine Maintenance - Coolant
Mixtures) If the system is being refilled, it is important
not to exceed the recommended fill rate of 10 litres
per minute.

A437760-V5

B
Fig 14.

6 Disconnect the condensation drain hoses from the a/

c unit.

7 Remove the bolts securing the evaporator/radiator

housing to the main casing.

8 Carefully pull the evaporator/radiator housing

complete with expansion valve from the main case.

9 The evaporator and the heater radiator can now be

lifted from the housing.

Replacement

Replacement is the reverse of the removal procedure but

take note of the following.

1 When refitting the unit care must be taken to allow the

condensation drain hoses to run downwards.(15C)
Do not cable tie the drain hoses so there is a uphill
run. Condensation could become trapped at this
point, leading to a build up of stagnant water.

B - 50 9803/4160-12 B - 50
 Section B - Body & Framework
Air Conditioning
Air Conditioning - 426 from M532100, 436 from M533700

Air Conditioning - 426 from M532100, 436 from M533700

The air conditioning system on the above machines (i.e.

Smoothshift machines) is identical in operation to the
system fitted on earlier machines.

The amount of refrigerant in the system is different - see

Technical Data ( B-1). The air conditioning switch
may be located either in the roof (early Smoothshift
machines) or in the side console (later Smoothshift
machines).

B - 51 9803/4160-12 B - 51
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

426 from M1231500, 436 from M1305000

The Air Conditioning Unit Note: There are no clips fitted to these hoses during
production. If the hoses are stretched to a point where they
The air conditioning unit (a/c) contains a blower unit; are not a snug push fit they should be replaced when
evaporator; heater radiator; filters and thermostat. It is refitting the unit.
located on the right side of the cab behind a hinged panel.

Note: Unlike the earlier models supplied by this

!MWARNING
manufacturer, the binary pressure switch is now located on The cooling system is pressurised when the coolant is
the receiver drier. hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before checking the coolant level or checking the
!MWARNING system.
The air conditioning system is a closed loop system 9-3-3-1_1
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has 5 Allow the engine to cool down. Slowly release the
been discharged by a refrigeration engineer or a filler cap to release any residual pressure. Refit the
suitably trained person. You can be severely cap once the pressure has been released.
frostbitten or injured by escaping refrigerant.
6 Loosen the coolant hose clips 3 and 5. Remove and
4-3-4-1_2
plug the hoses to prevent the loss of coolant.
Removal
7 Release the clips securing the control cables 4 and 9
Fig 17. ( B-54) to the heater coolant valve and the ventilation flap at
the control levers. Remove the cables.
The removal of the unit will require the assistance of a
refrigeration engineer or suitably qualified person since the
refrigerant will need to be discharged from the system
!MWARNING
When working on the Air Conditioning System,
1 Park the machine on firm level ground, apply the park gloves, eye protection and protective clothing must be
brake and put the transmission in neutral. Stop the worn. Do not smoke or expose refrigerant to naked
engine and remove the stater key to prevent the flames or hot surfaces.
engine being started while you are working on the BF-1-3
machine.
8 Ensure that the air conditioning system has been fully
2 Open the access panel on the right hand side of the discharged of its refrigerant by a refrigeration
machine. engineer or a suitably trained and qualified person.
Refrigerant Charging and
3 Remove the electrical harnesses 1 and 2 from the Discharging ( B-31).
heater blower motor and the air conditioning at the
their connections on the air conditioning cabinet. 9 With the system fully discharged, disconnect the high
and low pressure hoses 6 and 7 from their connection
Note: When facing the cabinet, the upper left hand wiring at the expansion valve 8.
harness connector is for the heater motor, the right hand
connector is for the air conducting. 10 Remove the seven bolts 16A securing the air
conditioning unit to the cab and with the aid of an
4 Reach under the side of the cab and remove the two assistant withdraw the unit.
air conditioning unit drain hoses from the unit by
pulling them from the units welded drain tubes. (Not
shown.)

B - 52 9803/4160-12 B - 52
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000




 


Fig 16.

Replacement

Fig 17. ( B-54).

Replacement is the reverse of the removal procedure,

however, note of the following:

1 When refitting the unit care must be taken to ensure

the condensation drain hoses are correctly routed.
There must be no kinks in the hoses and no ‘uphill
runs’ that would allow drained condensation to pool
which may result in a build up of stagnant water.

Important: If the cooling system has been drained, when

refilling, do not exceed the maximum fill rate of 10 litres per
minute.

2 When refilling the cooling system use the correct

water/antifreeze mixture. A 50% mixture should be
maintained even if frost protection is not required.
Refer to Section 3 - Routine Maintenance - Coolant
Mixtures.

3 The air conditioning system will need to be recharged

with refrigerant by a refrigeration engineer or suitably
trained and qualified person. Refrigerant
Charging and Discharging ( B-31).

B - 53 9803/4160-12 B - 53
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

 

 

 


Fig 17.

B - 54 9803/4160-12 B - 54
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Filters
Alongside the paper element filter fitted as 
an  filter can be fitted should operating  C
dictate.

Fig 20. ( B-57).

Removal

1 Open the access panel on the right hand side of the

machine.

2 Release the two ‘1/4 turn fasteners’ 18A securing the

filter cover to the main air conditioning cabinet.

Note: There is no need to remove the ventilation flap A B

control cable as there is sufficient flexibility in the cable to
allow the removal of the cover. Fig 18.

!MWARNING
Compressed air is dangerous. Wear suitable eye
protection and gloves. Never point a compressed air
jet at yourself or others.
0147_1

3 Remove the standard filter element 18B. Shake out

the loose dust and clean using low pressure
compressed air. Renew the filter if required.

4 If fitted, remove the secondary filter 18C by grasping

the removal tag at the top edge of the filter and
pulling.

Replacement

Replacement is the reverse of the removal procedure,

however, note the following:

– The secondary filter, regardless of its type, is secured

in position by two magnets. These magnets are a part
of the filter element, therefore care must be taken to
ensure the filter is installed the correct way round.

B - 55 9803/4160-12 B - 55
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Blower Motor 5 Withdraw the blower motor assembly 20-5 slowly

from the air conditioning cabinet until the wiring
For component layout see, Fig 20. ( B-57). connections at the motor are accessible. Label and
disconnect the wiring.
The blower motor is located inside the air conditioning unit.
The only user serviceable component being the resistor 6 Remove the thermostat from the heater blower
which governs the fan speed. other faults, with the support tray 20-4, Thermostat ( B-58).
exception of wiring defects, necessitate the replacement of
the blower motor as a unit. 7 Fully withdraw the blower motor assembly.

Note: The blower motor can be removed from the air Replacement
conditioning cabinet with the air conditioning assembly in
situ. Replacement is the reverse of the removal procedure.

Removal

1 Park the machine on firm level ground, apply the park

brake and put the transmission in neutral. Stop the
engine and remove the stater key to prevent the
engine being started while you are working on the
machine.

2 Open the access panel on the right hand side of the

machine.

3 Remove the filter housing and filter(s),

Filters ( B-55).

4 Remove the eight screws 19A securing the cover to

the air conditioning cabinet, and remove the cover.

 

 





Fig 19.

B - 56 9803/4160-12 B - 56
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000







Fig 20.
Component Key:
1 Filter Cover
2 Standard Air Filter Element
3 Secondary Filter Element (HEPA/ Carbon)
4 Blower Motor Support Tray
5 Blower Motor Assembly
6 Air Conditioning Cabinet
7 Heater Matrix
8 Expansion valve
9 Evaporator

B - 57 9803/4160-12 B - 57
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Thermostat 7 Disconnect the harness connection 22B to the

thermostat.
The thermostat monitors the external temperature of the
evaporator and is located within the air conditioning 8 Remove the securing bolts 22C Lift the thermostat
cabinet alongside of the blower motor. from the heater motor mounting plate and slowly
remove, withdrawing the probe from its hole through
Removal the mounting plate.

1 Park the machine on firm level ground, apply the park Replacement
brake and put the transmission in neutral. Stop the
engine and remove the stater key to prevent the Replacement is the reverse of the removal procedure.
engine being started while you are working on the
machine. Important: Care must be taken when inserting the
thermostat probe into the evaporator coil to ensure the
2 Open the access panel on the right hand side of the evaporator is not damaged.
machine.

3 Remove the filter housing and filter(s). 

Filters ( B-55).

4 Remove the eight screws 21A securing the cover to

the air conditioning cabinet, and remove the cover.

 

  


 Fig 22.



Fig 21.

5 Withdrawn the temperature probe 22A carefully from

the evaporator core.

6 Withdraw the heater motor sufficiently to secure

access to the thermostat securing bolts. Fig
20. ( B-57).

B - 58 9803/4160-12 B - 58
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Evaporator !MWARNING
The evaporator is located in the air conditioning cabinet. Its When working on the Air Conditioning System,
removal will require the assistance of a refrigeration gloves, eye protection and protective clothing must be
engineer or suitably qualified person since the refrigerant worn. Do not smoke or expose refrigerant to naked
will need to be discharged from the system flames or hot surfaces.
BF-1-3
Refer to Fig 17. ( B-54) and Fig 20. ( B-57).

Removal
!MWARNING
The air conditioning system is a closed loop system
1 Park the machine on firm level ground, apply the park and contains pressurised refrigerant. No part of the
brake and put the transmission in neutral. Stop the system should be disconnected until the system has
engine and remove the stater key to prevent the been discharged by a refrigeration engineer or a
engine being started while you are working on the suitably trained person. You can be severely
machine. frostbitten or injured by escaping refrigerant.
4-3-4-1_2
2 Open the access panel on the right hand side of the
machine. 5 Ensure that the air conditioning system has been fully
discharged of its refrigerant by a refrigeration
3 Remove the filter housing and filter(s). engineer or a suitably trained and qualified person.
Filters ( B-55). Refrigerant Charging and
Discharging ( B-31).
4 Remove the eight screws 23A securing the cover to
the air conditioning cabinet, and remove the cover. 6 With the system fully discharged, disconnect the high
(17-7) and low (17-6) pressure hoses from their
connection at the expansion valve 17-8.
  7 Remove the bolt 24A securing the expansion valve
24B to the cabinet.

 





Fig 23.

B - 59 9803/4160-12 B - 59
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Fig 24.

8 Carefully withdraw the evaporator unit 20-9, complete

with the expansion valve 20-8 from the air
conditioning cabinet.

Replacement

Replacement is the reverse of the removal procedure,

however note the following:

1 The air conditioning system will need to be recharged

with refrigerant by a refrigeration engineer or suitably
trained and qualified person. Refrigerant
Charging and Discharging ( B-31).

B - 60 9803/4160-12 B - 60
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Expansion Valve
The expansion valve is located on the air conditioning
cabinet.

Refer to Fig 17. ( B-54) and Fig 20. ( B-57).

Removal

1 Park the machine on firm level ground, apply the park

brake and put the transmission in neutral. Stop the 
engine and remove the stater key to prevent the
engine being started while you are working on the 
machine


2 Open the access panel on the right hand side of the
machine.

!MWARNING
When working on the Air Conditioning System,
gloves, eye protection and protective clothing must be Fig 25.
worn. Do not smoke or expose refrigerant to naked
flames or hot surfaces. 7 Remove the bolt 25A securing the expansion valve to
BF-1-3 the air conditioning cabinet and remove the valve
assembly.
!MWARNING 8 Remove and discard the O-rings from the pipes 25C
The air conditioning system is a closed loop system and D
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has Replacement.
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely Replacement is the reverse of the removal procedure,
frostbitten or injured by escaping refrigerant. however, note the following:
4-3-4-1_2
1 Always replace the pipe fittings O-rings with new.
3 Ensure that the air conditioning system has been fully
discharged of its refrigerant by a refrigeration 2 The air conditioning system will need to be recharged
engineer or a suitably trained and qualified person. with refrigerant by a refrigeration engineer or suitably
Refrigerant Charging and trained and qualified person. Refrigerant
Discharging ( B-31). Charging and Discharging ( B-31).

4 With the system fully discharged, disconnect the high

(17-7) and low (17-6) pressure hoses from their
connection at the expansion valve 17-8.

5 Peel back the insulation 25E from the pipes.

6 Disconnect the pipes 25C and D at the expansion

valve 25B.

B - 61 9803/4160-12 B - 61
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Heater Radiator
The heater radiator is located in the air conditioning
cabinet.

Refer to Fig 17. ( B-54) and Fig 20. ( B-57).


Removal

1 Park the machine on firm level ground, apply the park

brake and put the transmission in neutral. Stop the
engine and remove the stater key to prevent the
engine being started while you are working on the
machine.

2 Open the access panel on the right hand side of the

machine.

!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
Fig 26.
out and burn you. Make sure that the engine is cool
before checking the coolant level or checking the
7 Remove the four screws 27A securing the right hand
system.
access panel to the air conditioning cabinet and
9-3-3-1_1
remove the panel
3 Allow the engine to cool down. Slowly release the
filler cap to release any residual pressure. Refit the
cap once the pressure has been released.

4 Loosen the coolant hose clips 17-3 and 17-5.

Remove and plug the hoses to prevent the loss of 
coolant.

5 Release the clips securing the control cable 17-4 to

the heater coolant valve. Remove the cable.

6 Remove the upper hose clip 26A securing the heater

control valve 26B to the heater matrix and remove the
valve. 

Fig 27.

8 Withdraw the heater radiator 20-7 from the air

conditioning cabinet.

B - 62 9803/4160-12 B - 62
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000
Replacement.

Replacement is the reverse of the removal procedure,

however, note the following:

Important: If the cooling system has been drained, when

refilling, do not exceed the maximum fill rate of 10 litres per
minute.

1 When refilling the cooling system use the correct

water/antifreeze mixture. A 50% mixture should be
maintained even if frost protection is not required.
Refer to Section 3 - Routine Maintenance - Coolant
Mixtures.

B - 63 9803/4160-12 B - 63
 Section B - Body & Framework
Air Conditioning
426 from M1231500, 436 from M1305000

Binary Pressure Switch

The binary pressure switch assembly is located in the
engine compartment, screwed into the receiver drier unit.

Removal 

!MWARNING
Goggles and rubber gloves must be worn when
pressure switches are removed or fitted. A small
amount of refrigerant is released which can be harmful 
to the skin or eyes.
BF-1-10

1 Disconnect the battery.

2 Remove the harness connectors 28A, then unscrew

the pressure switch assembly 28B.

Replacement
Fig 28.
1 Screw the pressure switch 28B into the threaded port
and tighten sufficiently to form a gas-tight seal.

2 Reconnect the harness connectors 28A.

3 If the system is in an un-charged condition, charge

the air conditioning system. Refrigerant Charging
and Discharging ( B-31).

!MWARNING
Leak testing in Air Conditioning systems should be
carried out only in a well ventilated area.
BF-1-2

4 Operate the air conditioning system and check

around the pressure switch for leaks. If any leaks are
found, tighten the pressure switch further until the
leaking stops.

B - 64 9803/4160-12 B - 64
 Section B - Body & Framework

Cab
Glazing

Direct Glazing
TB-002_3
!MWARNING
The following procedures explain how to correctly remove Laminated glass must be handled with extra care to
and install panes of glass that are directly bonded to the prevent breakage. Wherever possible, store and
cab frame apertures. When carrying out the procedures, handle it in a vertical attitude. When placing or lifting
relevant safety precautions must be taken. the glass in a horizontal attitude it must be supported
over its whole area, not just at the edges.
1 Always wear safety glasses during both removal and BF-1-8_1
replacement.
Removing the Broken Glass and Old Sealant
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
!MWARNING
glass; surgical type gloves when using the Always wear safety glasses when removing or
polyurethane adhesives. installing screen glass. Never use a power operated
knife when removing the sealant around a toughened
3 Wear protective overalls. glass screen. The action of the knife could cause
particles of glass to be thrown with sufficient force to
4 Do not smoke - the activators and primers used in the cause serious injury, even when safety glasses are
procedures are highly flammable. being worn. Use only hand operated tools when
working with toughened glass.
5 Do not attempt to handle or move panes of glass BF-2-3_1
unless you are using glass lifters.
1 Position the machine on level ground and apply the
Several special tools are required to successfully complete parking brake. Stop the engine. Put protective covers
the removal and replacement procedures. Reference is over the cab seat and control pedestals.
made to the tools in the text. The majority of these tools
can be obtained locally and the remainder from JCB 2 If a laminated pane breaks it will stay in one piece
Service (see Service Tools). even though the glass is cracked. A toughened pane
will shatter and fall apart. The method of removal of
The work must only be carried out in a dry, frost free the glass depends upon which type it is.
environment. A protective canopy may be required or the
machine/frame must be moved to a sheltered area. In a Laminated glass - leave installed until the old
damp or wet conditions, hinged doors and window frames sealant has been cut away, after which it will be
can be removed from the machine and taken to a more possible to lift the broken screen away from its
suitable (dry) environment. frame housing in one piece.

Glass should not be replaced at temperatures below 5°C b Toughened glass - remove as much of the
(41°F). 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:

B - 65 9803/4160-12 B - 65
 Section B - Body & Framework
Cab
Glazing
a Pneumatic Knife. Fig 29. ( B-66). This
provides one of the easiest methods of removing
the sealant around laminated glass. The tool,
powered by compressed air, should be sourced
locally.

Fig 29. Pneumatic Knife

i Press the handle to start the knife blade

oscillating.

Important: This tool must not be used on toughened

glass.
Fig 30. Braided Cutting Wire and Handles
ii Insert the knife blade into the sealant.
ii Insert the braided cutting wire 30-B down the
centre of the steel tube. If necessary, from the
iii Slowly move the knife along the sealant with
outside, cut out local sealant at the point of the
the blade positioned as close to the glass as
tube to gain access to the wire.
possible. Do not allow the knife blade to
overheat or the sealant will melt.
iii Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the
b Braided Cutting Wire and Handles. Fig
glass.
30. ( B-66). This method uses a 3-core wire, a
wire starter tube and two handles.
iv Secure each end of the braided cutting wire in
the special handles 30-C.
i Insert the steel tube 30-A into the old sealant
on the inside of the glass.
v Move the cutting wire backwards and forwards
in a sawing motion and at the same time
gently push or pull the wire to cut through the
old sealant.

c Cut-out Knife. Fig 31. ( B-67). The cut-out

knife can be used as a left handed or right handed
tool.

B - 66 9803/4160-12 B - 66
 Section B - Body & Framework
Cab
Glazing
4 Laminated glass - lift out the broken pane using glass
lifters.

Toughened glass - remove the cut off sealant and all

remaining particles of shattered glass.

5 If necessary, trim off the remaining old sealant to

leave approximately 1 to 2 mm on the upright face of
the cab frame aperture. Fig 33. ( B-67)



Fig 31. Cut-out Knife

i Insert the knife blade into the sealant.

ii Make sure that the blade of the knife is against

the glass 31-A.

iii Use the 'pull-handle' to pull the knife along and Fig 33.
cut out the old sealant.
6 Apply a coat of 'Black Primer 206J' to the paintwork if:
d Craft Knife. Fig 32. ( B-67). The blades 32-A
are replaceable. a Paintwork was damaged or scratched during the
glass/sealant removal procedures.
i Insert the knife blade into the sealant.
b The old sealant was inadvertently cut back to the
ii Pull the knife along and cut out the old sealant. cab frame during the glass/sealant removal
procedures.

Preparing the Cab Frame Aperture

1 If damp or wet, dry the aperture area using a hot air

gun (sourced locally).

2 Use 'Active Wipe 205' to thoroughly clean and 'prime'

the trimmed sealant. Use a lint free cloth to apply the
'Active Wipe 205', allow 5 minutes flash off (drying)
time.

Fig 32. Craft Knife Note: Do not use any other type of cleaning fluids,
otherwise they may be absorbed into the old sealant and
Note: There are other tools available to cut out the old ultimately prevent the new glass from bonding.
sealant. For example, there is a long handle type craft knife
to give extended reach. Refer to Service Tools, for details
of this and any other tools.

B - 67 9803/4160-12 B - 67
 Section B - Body & Framework
Cab
Glazing
Preparing the New Glass 2 After checking for size, remove the new glass and
place it on a purpose made glass stand. Fig
35. ( B-68).
!MWARNING
Laminated glass must be handled with extra care to
prevent breakage. Wherever possible, store and
handle it in a vertical attitude. When placing or lifting
the glass in a horizontal attitude it must be supported
over its whole area, not just at the edges.
BF-1-8_1

1 Make sure that the new glass correctly fits the frame
aperture 34-A.

a Put two spacer blocks 34-B onto the bottom part

of the frame aperture.

b Install the new glass on the spacer blocks - Fig 35. Glass Stand
Always use glass lifters 34-C. Check that there is
an equal sized gap all round the edge of the glass. Small panes of glass will need locating on a 600 x 700
mm x 15 to 19 mm thick plywood board 36-A, sourced
Note: The spacer blocks are rectangular in section to give locally to fit the glass stand. It is recommended that
two common gap widths. If necessary they can be trimmed an access hole is cut in the board to accommodate
to a smaller size to give an equal sized gap around the the glass lifter, making it easier and safer to handle
glass. small panes of glass. The board should be covered
with felt or carpet to give an anti-scratch surface.
Important: The glass edges must not touch the frame, Resting the glass on four spacer blocks will ensure
otherwise movement of the frame will chip and eventually clearance of the cartridge nozzle tip during
break the newly installed glass. application of the polyurethane sealant.

Fig 36.

3 Make sure the glass is positioned on the stand the

correct way up (i.e. with the black ceramic ink band
upwards) ready for application of primer etc.

4 Clean the glass

Fig 34.
a Use 'Active Wipe 205' to thoroughly clean and
'prime' the black ceramic ink band printed on the

B - 68 9803/4160-12 B - 68
 Section B - Body & Framework
Cab
Glazing
glass (see Note). Use a lint free cloth to apply the
'Active Wipe 205', allow 5 minutes flash off
(drying) time.

Note: Do not touch the glass after cleaning with the 'Active
Wipe 205'.

b If the glass does not have a black ceramic ink

band, paint a band on the glass using 'Black
Primer 206J'. The band should be approximately
25mm (1in) wide, and the edge should be a neat Fig 38.
straight line. Fig 37. ( B-69).
6 Apply the pre-heated adhesive to the glass (do not
start in a corner). Keep the nozzle guide 39-A against
the edge of the glass and make sure that the
adhesive forms a continuous 'pyramid' shape. Fig
39. ( B-69)

Fig 37.

5 Install the Ultra Fast Adhesive cartridge (see Sealing

and Retaining Compounds, Section 1 and Note)
into a suitable applicator gun:
Fig 39.
a Remove the aluminium disc cover from the base
of the cartridge and discard the 'dessicant Note: Once the pre-heated adhesive has been applied to
capsule'. the glass, install the glass in the aperture as soon as
possible. After approximately 10 minutes the sealant will
b Make sure that the rolled edge of the cartridge is form a 'skin', this will prevent the glass from bonding.
not damaged - if necessary, the edges should be
pressed flat, otherwise it will be difficult to remove 7 After applying the adhesive, leave a small amount of
the cartridge from the applicator gun. sealant protruding from the nozzle. This will prevent
any adhesive left in the cartridge from 'curing'.
c Pierce the front 'nozzle' end of the cartridge to its
maximum diameter.
Installing the New Glass
d Fit the pre-cut nozzle. Fig 38. ( B-69).
1 If the internal trim strip is damaged, renew it (cut to
length as required) before fitting the new glass. Make
e Install the cartridge in the applicator gun.
sure the two spacer blocks are in position.
Preparing the New Glass ( B-68) - step 1.
Note: Cold material will be very difficult to extrude. The
cartridges must be pre-heated in a special oven for 1 hour
2 Install the glass in the frame aperture:
to a temperature of 80°C (176°F). Pre-heating the
cartridges makes the adhesive more workable and also
a Always use the special lifting tools when moving
brings the 'curing' time down to 30 minutes.
the glass. Use a lifting strap to hold large panes of
glass in position. Fig 40. ( B-70)

B - 69 9803/4160-12 B - 69
 Section B - Body & Framework
Cab
Glazing
4 All exposed edges must be sealed using Black
Polyurethane Sealant (see Sealing and Retaining
Compounds, Section 1).

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.

5 Clean the glass after installation:

a Small amounts of sealant can be cleaned from the

glass using the 'Active Wipe 205'.
Fig 40. Typical M/c. Installation
b Large amounts of excess sealant should be left to
b Sit the bottom edge of the glass on the spacer
'cure' and then cut off with a sharp knife.
blocks. Fig 41. ( B-70)
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.

c Clean the glass using a purpose made glass

cleaner

6 On completion of the glass installation procedures

tidy the work area:

a Remove all broken glass from the cab area.

b Remove the protective covers from the cab seat

and control pedestals.

c Renew all 'warning' and 'information' decals so

that the new installation conforms with the original
cab installation.

Fig 41.

c Make sure that the glass is correctly positioned,

then gently press around the edges of the glass
and ensure full adhesive contact is achieved. Do
not press too hard or too much adhesive will
squeeze out.

3 Make the inside seal smooth:

a Wearing surgical gloves, dip your finger in a

soapy water solution.

b Use your finger to make the inside seal smooth.

B - 70 9803/4160-12 B - 70
 Section B - Body & Framework
Cab
ROP/FOPS Structure

ROP/FOPS Structure

426 prior to M1231500, 436 prior to

M1305000
Checking the Structure

!MWARNING
If the machine is fitted with a Roll Over Protection
Structure (ROPS) and/or a Falling Objects Protection
Structure (FOPS), you could be killed or seriously
injured if you operate the machine with a damaged or
missing ROPS/FOPS. If the ROPS/FOPS has been in
an accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_5

1 Check the structure for damage.

2 Make sure that all the ROPS/FOPS mounting bolts

42A are in place and undamaged.

3 Make sure that the ROPS/FOPS mounting bolts 42A Fig 42.
are tightened to the correct torque setting. This
should be 330 Nm (243 lbf ft).

B - 71 9803/4160-12 B - 71
 Section B - Body & Framework
Cab
ROP/FOPS Structure

426 from M1231500, 436 from M1305000

Checking the Structure

!MWARNING
If the machine is fitted with a Roll Over Protection
Structure (ROPS) and/or a Falling Objects Protection
Structure (FOPS), you could be killed or seriously
injured if you operate the machine with a damaged or
missing ROPS/FOPS. If the ROPS/FOPS has been in
an accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_5

1 Check the structure for damage.

2 Make sure that all the ROPS/FOPS mounting bolts

43A are in place and undamaged.

3 Make sure that the ROPS/FOPS mounting bolts 43A 

 

are tightened to the correct torque setting. This Fig 43.
should be 270 Nm (199 lbf ft).

B - 72 9803/4160-12 B - 72
 Section B - Body & Framework

Bodywork
Removal and Replacement of the Rear Bodywork

On 426 models from M1231500 and 436 models from 5 Remove the six bolts securing the fan grille to the fan
M1305000 it will be necessary to remove the rear housing. (The lower three are fitted on the under side
bodywork section covering the engine and cooling pack to of the grille.)
carry out certain essential maintenance tasks.

To remove the bodywork proceed as follows:

!MWARNING
Hydraulic Pressure
Removal Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
1 Park the machine on firm level ground, lower the or couplings, vent the pressure trapped in the hoses in
attachments to the ground, apply the park brake and accordance with the instructions given in this
set the transmission to neutral. Stop the engine. Block publication.
both sides of all four wheels. HYD-1-5

Important: The procedure detailed below must be 6 Label and disconnect the hoses to the cooling fan
followed to correctly vent the residual hydraulic pressure. motor 45A, 45B and 45C. Plug the hoses and cap the
open motor ports to prevent the ingress of dirt or
2 Vent the hydraulic pressure as detailed in Section E debris. Section E - Hydraulics - Service
- Hydraulics - Service Procedures - Venting the Procedures - Connecting and Disconnecting
System Pressure. Hydraulic Hoses.

3 Disconnect the batteries to prevent the engine being

started whilst carrying out this procedure.

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

From inside the right-hand side cover pull the release
cable 44A to unlatch the rear fan housing assembly.




Fig 45.

7 Remove the plastic body panel fitted above the fan

housing covering the upper rear bodywork support
panel.

8 Feed the released fan hydraulic hoses up through the
top of the fan housing, through the upper bodywork
Fig 44.

B - 73 9803/4160-12 B - 73
 Section B - Body & Framework
Bodywork
Removal and Replacement of the Rear Bodywork
support panel and rest over the right-hand side 14 Disconnect the coolant top hose from its connections
chassis. at the cooling pack and the engine and remove the
hose from the bulkhead. Plug the open ports to
9 Raise the fan housing fully on its gas struts, attach a prevent dirt ingress.
suitable sling to the motor and connect the sling to a
overhead crane. Fig 46. ( B-74). 15 Disconnect the two small bore coolant hoses 47A and
47B from the header tank where they are connected
to the steel pipes just on the engine side of the rear
bulkhead on the right-hand side of the machine. The
hose to the engine can be left connected at the
engine end. The hose passing through the bulkhead
to the cooling pack should be pulled through the
bulkhead but can be left secured at the cooling pack
connection.

Fig 46.

10 With the weight of the fan motor and housing
assembly held by the overhead crane, release the
two gas struts from the fan housing.

11 Working from inside the fan housing aperture, remove
the four bolts securing the fan housing top hinges to Fig 47.
the upper rear bodywork support panel and slide the
assembly away from the rear of the machine until the 16 Disconnect the exhaust flexi-pipe at the silencer and
hinges are free of the panel. Lower the fan housing the engine and remove. Plug the open ports to
assembly to the ground and stow safely. prevent any ingress of dirt or debris. The silencer
should be left secured to the bodywork.
12 Disconnect the charge air cooler steel pipe at the
hose connections each side of the rear engine 17 Disconnect the air cleaner hose between the filter
bulkhead. Plug the open ports and hoses and remove housing and the engine. Plug the open ports to
the steel pipe from the rear bulkhead. prevent any ingress of dirt or debris. The air cleaner
assembly can be left secured to the bodywork.
Note: Access to the cooling pack sections drain plugs is
via holes machined into the rear panel beneath the 18 Label and disconnect the harness from the air filter
batteries accessed from the rear. restriction switch. Release the harness from its
securing at the bulkhead
13 Drain the coolant from the cooling pack radiator
section into a suitable container. (Cover the container 19 Disconnect the large bore coolant hose from the
to prevent dirt ingress if the coolant is to be reused. If header tank. Plug the open hose to prevent the
the coolant is to be discarded, dispose of in an ingress of dirt or debris. The header tank can be left
environmentally friendly manner in line with local secured to the bodywork.
legislation.)

B - 74 9803/4160-12 B - 74
 Section B - Body & Framework
Bodywork
Removal and Replacement of the Rear Bodywork
20 Label and disconnect the grid heater harness cable
48A from the solenoid attached to the front bulkhead.
Label and disconnect the grid heater solenoid
activation cables 48B and 48C from the solenoid and,
release the harness from its bulkhead securing
fasteners.

 Fig 49.
 22 label and disconnect the emergency steer motor feed
cable 50A at its connection at the solenoid. Also label
and disconnect the solenoid operating harness
cables 50B and C. Release the operating harness
from its bulkhead securing fasteners. The solenoid
can be left attached to the bulkhead.

Fig 48.

21 Label and disconnect the emergency steer positive
feed cable 49A from its connection at the fusible link
on the bulkhead.


Fig 50.

B - 75 9803/4160-12 B - 75
 Section B - Body & Framework
Bodywork
Removal and Replacement of the Rear Bodywork
23 Remove the bolts securing the emergency steering 27 Securely fit the lifting eyes to the threaded holes
motor/pump and electrical units to the front bulkhead. provided in the rear bodywork and attach suitable
Secure the components to the engine so that the lifting slings. Securely attach the slings to an
weight of the assembly is not hanging on the electrical overhead crane.
harness or the hydraulic hoses.
28 Remove the four bolts 52A (two each side) securing
24 Label and disconnect the rear and engine harness the rear bodywork securing panel to the cast rear
connections at their connections through the front corner uprights.
bulkhead on the right-hand side of the machine.
Fig 51. ( B-76).



Fig 52.

29 Remove the four bolts 53A (two each side) securing

the rear bulkhead to the chassis.


Fig 51. Note: It will be necessary to simultaneously feed the main

transmission hydraulic hose and the two smaller engine
25 Remove the two bolts securing the fuel sedimenter fan hydraulic hoses 53B and 53C through the apertures in
bowl to the rear bulkhead and temporarily secure the the lower left hand and right-hand corners of the rear
sedimenter to the engine. There is no need to bulkhead as the bodywork is lifted.
disconnect the fuel pipes to the sedimenter.

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

26 Remove the two bolts securing the air conditioning

receiver drier to the rear bulkhead and secure the
receiver drier to the chassis or engine. DO NOT
release the air conditioning hoses at the receiver
drier.

B - 76 9803/4160-12 B - 76
 Section B - Body & Framework
Bodywork
Removal and Replacement of the Rear Bodywork

Replacement
Replacement is the reverse of the removal procedure,
 however note the following:

1 Remember to feed the two fan hydraulic hoses and

the transmission hose up through the apertures in the
 lower corners of the rear bulkhead as the bodywork is
lowered into place.

!MWARNING
Fluid Under Pressure
 Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
 pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
Fig 53. skin, get medical help immediately.
INT-3-1-10_2
30 Remove the four bolts 54A (two each side) securing
the bodywork to the front bulkhead supports. (The 2 All hydraulic hose sealing O-rings must be replaced.
upper bolt each side is adjacent to the cab mounting.) Do not over tighten the Allen bolts 55A securing the
hose flanges to the cooling pack. See Table 2.
Torque Settings ( B-78).

3 Top up all fluids as necessary using the correct grade

of fluid for each system. Refer to Section 3 - Routine
Maintenance.


!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1

4 The correct concentration of coolant antifreeze is to

be added to the cooling system. A 50% antifreeze
mixture should be used even if frost protection is not
needed. This gives protection against corrosion and
raises the coolants boiling point.


Fig 54. 5 To provide sufficient corrosion protection,

Supplemental Coolant Additive (SCA) must be added
31 Using the overhead crane and, whilst checking for to the coolant mixture. The coolant filter provides the
unreleased connections, slowly lift the complete rear required amount of SCA, provided it is replaced at
bodywork section from the machine. Once clear of regular intervals. If the drained coolant is to be reused
the machine lower the bodywork section to the then no action need be taken other than renewing the
ground and secure. coolant filter at its scheduled time. If however the
coolant is to be replaced with a fresh coolant mixture,
it is advisable to renew the coolant filter

B - 77 9803/4160-12 B - 77
 Section B - Body & Framework
Bodywork
Removal and Replacement of the Rear Bodywork
Note: It is recommended that the cooling system be filled
at a maximum rate of 10 litres per minute. If the fill rate is
any higher than this there is a possibility of air becoming
trapped in the system.

6 When refitting the batteries, make sure they are

connected in the correct manner by connecting the
earth lead last.

Table 2. Torque Settings

Item Nm kgf m lbf ft
A (1) 25 2.5 18
Coolant drain 55 5.6 40
plug

(1) Allen Bolt

Fig 55.

B - 78 9803/4160-12 B - 78
 Section B - Body & Framework


Removal and Replacement

Removal a Remove split pin 1-22 and castellated nut 1-21

then withdraw bolt 1-17 complete with washers 1-
Park the machine in the straight-ahead position on firm, 28.
level ground. Lower the shovel flat onto sliders resting on
the ground. Apply the transmission brake. Select neutral b Remove bolts 1-23 and washers 1-24 and remove
and switch off the engine. Operate the hydraulic controls to end caps 1-5.
vent system pressure.
c Drive out pivot pin 1-1, taking care to retain shims
1 Securely block all wheels on both sides. 1-9 to 1-14 and washers 1-26.

2 Remove the cab, refer to Removal and d Remove and discard bearings 1-18. Remove and
Replacement ( B-79). discard lip seals 1-7.

3 Remove the pin from each steering ram rod end. 10 Remove the blocks from under the front wheels.
Move the steering rams clear of the front chassis.
11 Release the parking brake and manually separate the
4 Disconnect the driveshaft at the brake disc flange. front and rear chassis just sufficiently to enable work
Mark all four flanges to ensure correct re-assembly. to be carried out on the centre pivot.

5 Separate the two halves of the hydraulic pipe clamp

to release the hydraulic pipework.

Note: There should be sufficient slack in the hydraulic

pipework to allow the front and rear chassis to be
separated without the pipework having to be disconnected.
When separating the chassis, take care not to put undue
strain on the hydraulic pipework.

6 Using suitable blocks, support the rear chassis at

front and rear.

7 Place a trolley jack under the lower pivot flange of the

front chassis after putting a piece of timber between
the contact points.

8 Remove the lower pivot pin as follows:

a Remove screw 1-3, washer 1-4 and spacer 1-31.

b Drive out pivot pin 1-2, taking care to retain shims

1-30 and bearing 1-20. Discard seals 1-6.

9 Remove the upper pivot as follows:

B - 79 9803/4160-12 B - 79
 Section B - Body & Framework
Centre Pivot
Removal and Replacement

Fig 1.

B - 80 9803/4160-12 B - 80
 Section B - Body & Framework
Centre Pivot
Removal and Replacement

Replacement 7 Add dimension d to dimension t which is stamped on

the front module. This dimension (d + t) equals the
Fit new bearings 18 during reassembly. This will shims required to give the correct clearance.
necessitate setting up shims 9 to 14 using a dummy boss
and bearing locator, see Numerical List Section B - 8 Select shims from the table corresponding to
Body and Framework ( 1-5), to give correct clearance. dimension (d + t) and insert underneath bearing
Proceed as follows: locator B.

1 Grease the face of the bottom end cap 5. Assemble Note: If no dimension t is stamped, read dimension t as
the bottom bearing cup to the housing and secure zero
using bolts 23 and washer 24. Torque tighten bolt.
9 Bearing locator should now project above face X by
2 Pack the bottom bearing with grease and fit into the an amount equivalent to dimension t ± 0.025 mm.
new bearing cup.
10 Remove bearing locator B, shim pack, top bearing
Note: Ensure that the bearing is completely filled with and dummy boss A.
grease.
11 Fit new lip seals 7 over the large diameter portion of
3 Position dummy boss A into bottom bearing. the rear module pivot boss, or alternatively rolled
inside out to protect the seal lips during chassis
4 Position the top bearing on top of dummy boss A. mating.
Holding the top bearing, rotate the dummy boss three
or four times to seat the rollers. 12 Position the top bearing cone on pivot pin 1 to
dimension Y (178 mm) as shown.
5 Position bearing locator B into top bearing.

6 Measure gap d between the top of bearing locator B

and face X.

Fig 3.

13 Smear the bottom portion of the rear module pivot

bore with locking fluid.
Fig 2.

B - 81 9803/4160-12 B - 81
 Section B - Body & Framework
Centre Pivot
Removal and Replacement
14 Remove bottom end cap 5, fit washer 26 and replace
Shim Part No. Nominal Thickness mm (in)
the bottom end cap. Torque tighten screw 23.
A 819/00029 1.0 (0.039)
15 Carefully mate the front and rear chassis. B 819/00030 0.25 (0.010)
C 819/00031 0.15 (0.006)
16 Assemble the lower pivot pin 2 together with shims
30, bearing 20 and new seals 6. Retain with spacer D 819/00035 0.6 (0.024)
31, washer 4 and screw 3. Torque tighten screw. E 819/00037 0.9 (0.035)

17 Smear locking fluid onto the top portion of pivot pin 1 F 819/00036 0.7 (0.028)
and assemble through housing and boss.

18 Pack the top bearing with grease and fit the bearing
cup. Dimension (d + t) Shims
mm (in)
Note: Ensure that the bearing is completely filled with
grease. 0.83 - 0.87 (0.033 - 0.034) D+B
0.88 - 0.92 (0.035 - 0.036) E
19 Fit the shim pack and washer 26. 0.93 - 0.97 (0.037 - 0.038) F+B
20 Grease the face of the top end cap 5 then secure with 0.98 - 1.02 (0.039 - 0.040) A
washers 24 and bolt 23. Torque tighten bolt. 1.03 - 1.07 (0.040 - 0.042) E+C
1.08 - 1.12 (0.042 - 0.044) D+2xB
21 Fit bolt 17, washers 28 and castellated nut 21. Torque
tighten nut then fit new split pin 22. 1.13 - 1.17 (0.044 - 0.046) A+C
1.18 - 1.22 (0.046 - 0.048) 2xD
Note: If necessary, the castellated nut can be further
1.23 - 1.27 (0.048 - 0.050) A+B
tightened until the next castellation lines up with the split
pin drilling in the bolt. 1.28 - 1.32 (0.050 - 0.052) D+F

22 Manoeuvre lip seals 7 into position.

23 Apply grease through each of the nipples until it is

emitted through the lip seals.

The remainder of the procedure is a reversal of the

removal procedure.

Table 1. Torque Settings

Item Nm kgf m lbf ft
3 244 24.9 180
21 68 6.9 50
23 98 10.0 72

B - 82 9803/4160-12 B - 82
 Section B - Body & Framework
Centre Pivot
Removal and Replacement

Dimension (d + t) Shims
mm (in)
1.33 - 1.37 (0.052 - 0.054) 2xD+C
1.38 - 1.42 (0.054 - 0.056) 2xF
1.43 - 1.47 (0.056 - 0.058) F+D+C
1.48 - 1.52 (0.058 - 0.060) D+E
1.53 - 1.57 (0.060 - 0.062) 2xF+C
1.58 - 1.62 (0.062 - 0.064) A+D
1.63 - 1.67 (0.064 - 0.066) D+E+C
1.68 - 1.72 (0.066 - 0.068) A+F
1.73 - 1.77 (0.068 - 0.070) E+F+C
1.78 - 1.82 (0.070 - 0.072) 2xE
1.83 - 1.87 (0.072 - 0.074) B+E+F
1.88 - 1.92 (0.074 - 0.076) A+E
1.93 - 1.97 (0.076 - 0.078) A+B+F
1.98 - 2.02 (0.078 - 0.079) 2xA
2.03 - 2.07 (0.080 - 0.081) A+C+E
2.08 - 2.12 (0.082 - 0.083) 2xD+E
2.13 - 2.17 (0.084 - 0.085) 2xA+C
2.18 - 2.22 (0.086 - 0.087) D+E+F
2.23 - 2.27 (0.088 - 0.089) 2xA+B
2.28 - 2.32 (0.090 - 0.091) 2xF+E

B - 83 9803/4160-12 B - 83
 Section B - Body & Framework

Cooling Pack


A new cooling pack has been fitted to the 426 models from
the above serial numbers.

This is a combination pack. It provides all the necessary

cooling activities for the machines components with the
exception of the Air Conditioning. (It should be noted that
whilst most machines are fitted with air conditioning, it is an
optional fitment. Its fitment or not makes no difference to
the main cooling packs function.)

When viewed from the engine side 1A, the individual

sections of the cooling pack are: 1-1 Turbo Intercooler, 1-2
Transmission Oil Cooling, 1-3 Engine Coolant Radiator
and 1-4 Hydraulic Oil Cooling.

The cooling pack sections are held together by top and

bottom holding plates 1B and 1C. By removing the section
securing bolts 1-5 and 1-6, it is possible to remove and
replace a single section. (See Dismantling and
Assembly ( B-90))

It is intended that to replace a single section the complete Fig 1.

pack will need to be removed from the machine.

Key
7 
8 

B - 84 9803/4160-12 B - 84
 Section B - Body & Framework
Cooling Pack
426 from Serial No. 532500

Removal and Replacement (426 from

Serial No. 532500)
Removal

The cooling pack is a combination unit that cools water, air,

transmission and hydraulic oils. Before attempting to work
on the cooling pack unit, all appropriate safety measures
must be taken.

1 Park the machine on firm level ground and lower the

loader arms. Engage the parking brake. Put the
transmission in neutral and chock both sides of all
four wheels. Stop the engine and let it cool down.
Operate the hydraulic control levers to release
pressure trapped in the hoses then remove the
hydraulic tank filler cap. Refit the cap once any
residual pressure has been released. Fig 2.

!MWARNING 3 Remove drain plug 3-2 from the radiator section of the
cooling pack and drain the coolant. Renew the drain
Hydraulic Pressure plug aluminium washer, refit the drain plug and torque
Hydraulic fluid at system pressure can injure you. tighten. See Table 1. Torque Settings ( B-89)
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

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

!MWARNING
Hot Coolant
The cooling system is pressurised when the engine is
hot. Hot coolant can spray out when you remove the Fig 3.
filler cap. Let the system cool before removing the
filler cap. To remove the cap; turn it to the first notch !MCAUTION
and let the system pressure escape, then remove the
cap. Keep your face away from the drain hole when
removing the drain plug.
INT-3-2-9_1
2-3-3-4
2 Carefully loosen cap 2-1. Let any pressure escape.
Remove the cap. (Access to the cap is through the 4 Remove the cylinder block drain plug 4-3 and drain
opening cut into the top of the engine cover). the coolant. Clean and refit the drain plug.

B - 85 9803/4160-12 B - 85
 Section B - Body & Framework
Cooling Pack
426 from Serial No. 532500

Fig 4.

5 Remove the batteries to prevent the terminals being

shorted out whilst removing air conditioning and
engine cover components.
Fig 5.
6 Disconnect the air conditioning condenser from its
Note: Do not disconnect the air conditioning hose
upper and lower mounting points to the right hand
connections at the receiver drier. (See above warning.)
engine cover and stow clear of the cooling pack. (The
condenser unit complete with its pipework can be laid
8 Arrange slings from the four points in the engine
into the battery holding bay or on the rear chassis.)
cover to an overhead crane. (Eye bolts can be
securely screwed into the four threaded lifting point
Note: Do not disconnect the air conditioning hose
holes. The holes are plugged with plastic bungs.)
connections at the condenser.
9 Remove the exhaust silencer at its connection where
!MWARNING it comes through the engine cover.
The air conditioning system is a closed loop system
10 Remove the air cleaner induction hose at its
and contains pressurised refrigerant. No part of the
connection to the filter housing. (Cap the open end of
system should be disconnected until the system has
the hose to prevent dirt entering the intake). Also
been discharged by a refrigeration engineer or a
remove the electrical connector from the vacuum
suitably trained person. You can be severely
switch in the induction pipe. (The air cleaner
frostbitten or injured by escaping refrigerant.
assembly can be left attached to the engine cover.)
4-3-4-1_2

11 Remove the hose connections to the header tank.

7 Disconnect the air conditioning receiver drier from the
(The tank can be left in position on the engine cover.)
right hand cooling pack cowl by removing the two
securing bolts 5-4. Disconnect the pipe clamp from
12 Remove the two bolts 6-5 securing the fuel
the cowl securing bolt 5-4A.
sedimenter bowl to the engine cover. (Secure the fuel
sedimenter to a suitable place on the engine whilst
adrift from its mounting point. Take care not to kink the
fuel pipes by allowing the sedimenter to hang loose.)

B - 86 9803/4160-12 B - 86
 Section B - Body & Framework
Cooling Pack
426 from Serial No. 532500

Fig 7.

16 Remove the six front retaining bolts 8-7. (Three from

each side in the engine cover.)

Fig 6.

13 Disconnect the wiring harness to the reverse alarm

and the rear worklights and release it from its
fastenings to the right hand engine cover.
Fig 8.
14 Remove the two bolts securing the battery isolator
switch to the right hand side engine cowl. 17 Remove the cooling pack to engine cowl upper
mounting bolts 9-8.
15 Remove the four rear retaining bolts 7-6. (Two from
each side in the engine cover.)

B - 87 9803/4160-12 B - 87
 Section B - Body & Framework
Cooling Pack
426 from Serial No. 532500

Fig 10.

!MWARNING
Take care when disconnecting hydraulic hoses and
Fig 9. fittings as the oil will be HOT.
TRANS-1-2
18 Using the overhead crane lift the engine cover from
the machine. 22 Disconnect the top and bottom hydraulic hoses at the
cooling pack by removing the four Allen screws 11-10.
19 Lower the assembly to the ground and secure. If there are no tags on the hoses, tie on your own to
aid correct refitment. Cap the open hoses and ports.
20 Disconnect the top and bottom coolant hoses

21 Disconnect the top and bottom turbo intercooler

hoses 10-9 from the cooling pack. Cap the ends of the
hoses and the ports to the cooling pack

Fig 11.

23 Disconnect the top and bottom transmission hoses at

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

24 Remove the engine cooling fan.

B - 88 9803/4160-12 B - 88
 Section B - Body & Framework
Cooling Pack
426 from Serial No. 532500
25 Arrange slings from the cooling pack lifting eyes
(welded into the top mounting plate) to the overhead
!MWARNING
crane. Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
Note: Do not lift the cooling pack by attaching lifting hooks antifreeze.
or eyes to the cooling packs top mounting points. The pack 7-3-4-4_1
sides can be distorted leading to a failure of the packs
section 3 When refitting the batteries, make sure they are
connected in the correct manner by connecting the
26 Disconnect the two lower cooling pack retaining bolts earth lead last.
12-11 from the brackets to the chassis.
Table 1. Torque Settings
Item Nm kgf m lbf ft
2 55 5.6 40
10 25 2.5 18

Fig 12.

27 Using the overhead crane lift the cooling pack from

the machine.

Replacement

Replacement is the reverse of removal but note the

following:

1 All hydraulic hose sealing “O” rings must be replaced.

Do not over tighten the Allen screws 11-10 see
Table 1. Torque Settings ( B-89).

2 The correct concentration of coolant antifreeze is to

be added to the cooling system. A 50% antifreeze
mixture should be used even if frost protection is not
needed. This gives protection against corrosion and
raises the coolants boiling point.

Note: It is recommended that the cooling system be filled

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

B - 89 9803/4160-12 B - 89
 Section B - Body & Framework
Cooling Pack
426 from Serial No. 532500

Dismantling and Assembly Assembly

Dismantling Assembly is the reverse of removal but note the following:

1 Remove the upper section securing bolts 13A and the 1 Keep all ports covered until the relevant connection
lower securing bolts 13B, that hold the required are to be made, to keep dirt and debris from entering
individual section to the upper and lower mounting the pack sections.
plates.
2 Refit the pack sections using the correct length bolts.
2 Slide the section from the pack. (The pack section could be severely damaged by
inserting bolts of an incorrect length.)
Note: Do not use excessive force to remove the section, or
use a pry bar against the section securing plates. If 3 If the engine coolant section is being replaced ensure
necessary slacken the other sections securing bolts to that the drain plug 13-2 is installed using a new
relieve the pressure on the section to be removed. aluminium washer and that it is tightened to the
correct torque. (See Table 1. Torque Settings
( B-89).)

Fig 13.

B - 90 9803/4160-12 B - 90
 Section B - Body & Framework
Cooling Pack
436 from Serial No. 534200



A new cooling pack has been fitted to the 436 models.

This is a combination pack. It provides all the necessary

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

The cooling packs individual sections stand vertically.

When viewed from the engine side 14-A the sections are
14-1 Turbo Intercooler, 14-2 Transmission Oil Cooling, 14-
3 Engine Coolant Radiator and 14-4 Hydraulic Oil Cooling.

The cooling packs modular design means an individual

section can be renewed without the need to replace the
whole pack.

It is intended that to renew a single section the complete

pack will need to be removed from the machine.

See the following pages for details of repair operations.

Fig 14.
Key
5 
6 
7 
8 
9 
10 

B - 91 9803/4160-12 B - 91
 Section B - Body & Framework
Cooling Pack
436 from Serial No. 534200

Removal and Replacement 6 Disconnect the turbo intercooler pipes from the
cooling pack. Cap the ends of the hoses and the ports
Removal to the cooling pack.

The cooling pack is a combination unit that cools water; 7 Remove the engine coolant section drain plug and
turbo charged air; transmission and hydraulic oils. Before drain the coolant. Discard the aluminium sealing
attempting to work on the cooling pack unit all safety washer and fit a new one. Refit the drain pug and
measures must be taken. torque tighten to 55 Nm (40lbf ft).

1 Park the machine on firm level ground and lower the 8 Remove the coolant hoses from the cooling pack.
loader arms. Engage the parking brake. Put the
transmission into neutral and chock both sides of all !MWARNING
four wheels. Stop the engine and let it cool down.
Operate the hydraulic control levers to release Hydraulic Pressure
pressure trapped in the hoses, then remove the Hydraulic fluid at system pressure can injure you.
hydraulic tank filler cap. Refit the tank cap once any Before connecting or removing any hydraulic hose,
residual pressure has been released. 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
!MCAUTION hoses. Make sure the engine cannot be started while
Batteries the hoses are open.
To prevent the engine being started, disconnect the INT-3-1-11_2
battery while working on the cooling pack.
0109

2 Open the rear grille and remove the reverse alarm

from its mounting by removing the two securing bolts.

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

4 Secure slings to the rear pod and using an overhead

crane lift the pod away from the machine.

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

5 Carefully loosen the coolant filler cap. Let any

pressure escape. Remove the filler cap. (Access to
the filler cap is through a hole cut into the top of the
engine cover.

B - 92 9803/4160-12 B - 92
 Section B - Body & Framework
Cooling Pack
436 from Serial No. 534200

Key !MWARNING
1 Coolant Filler Access Point Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
2 Coolant Filler Cap
TRANS-1-2
3 Bodywork Pod
4 Engine Cover 10 Disconnect the hydraulic system hoses by undoing
the four Allen bolts 16A that secure the hose flange to
5 Rear Grille the cooling pack port. If there are no tags on the
6 Side Access Panel hoses, tie on your own to aid correct refitment. Cap
7 Pod Securing Bolts x3 the open ports and hoses to prevent any dirt or debris
entering the cooling pack or the hoses.
8 Pod Side securing Bolts x 2
9 Pod Lower Securing Bolt x 1 11 Disconnect the hydraulic hoses from the fan motor.
Cap the open ports and hoses to prevent dirt or debris
Note: Items 15-8 and 15-9 are repeated on the other side entering the system.
of the machine
12 Disconnect the air conditioning condenser from its
mountings and stow on the rear chassis clear of the
cooling pack.

Note: Do not disconnect the air conditioning hoses at their

connections to the condenser.

!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system has
been discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
4-3-4-1_2

13 Arrange slings from the overhead crane to the lifting

points on the top of the cooling pack. (Do not lift the
cooling pack by any means other than these lifting
points.)

14 Remove the left hand and right hand side chassis

mounting bracket bolts.

Fig 15. 15 Remove the bottom mounting bolts.

9 Disconnect the transmission hoses by undoing the 16 Using the overhead crane slowly lift the cooling pack
four Allen bolts 16A that secure the hose flange to the clear of the machine. Lower the cooling pack to the
cooling pack port. If there are no tags on the hoses, ground and secure.
tie on your own to aid correct refitment. Cap the open
ports and hoses to prevent any dirt or debris entering Replacement
the cooling pack or the hoses.
Replacement is the reverse of removal but note the
following:

B - 93 9803/4160-12 B - 93
 Section B - Body & Framework
Cooling Pack
436 from Serial No. 534200
1 All hydraulic hose sealing “O” rings must be replaced.
Do not over tighten the Allen bolts 16A securing the
hose flange to the cooling pack. See Table 2.
Torque Settings ( B-94).

2 The correct concentration of coolant antifreeze is to

be added to the cooling system. A 50% antifreeze
mixture should be used even if frost protection is not
needed. This gives protection against corrosion and
raises the coolants boiling point.

Note: It is recommended that the cooling system be filled

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

!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1

3 When refitting the batteries, make sure they are

connected in the correct manner by connecting the
earth lead last.

Table 2. Torque Settings

Item Nm kgf m lbf ft
A(1) 25 2.5 18
Coolant 55 5.6 40
drain
Plug

(1) Allen bolt

Fig 16.

B - 94 9803/4160-12 B - 94
 Section B - Body & Framework
Cooling Pack
436 from Serial No. 534200

Dismantling and Assembly

Dismantling

1 Remove the bolts securing the fan cowl to the cooling

pack. (The cooling fan, fan motor and mounting frame
can be left attached to the cowl.)

2 Remove the section securing bolts 17-11 that hold the

required individual section to the mounting plates.

3 Slide the section from the pack.

Note: Do not use excessive force to remove the section, or

use a pry bar against the section securing plates. If
necessary slacken the other sections securing bolts to
relieve the pressure on the section to be removed.

Assembly

Assembly is the reverse of removal but note the following:

1 Keep all ports covered until the relevant connections

are to be made, to keep dirt and debris from entering
the pack sections.

2 Refit the pack sections using the correct length bolts.

(The pack section could be severely damaged by
inserting bolts of an incorrect length.)

3 If the engine coolant section is being replaced ensure

that the drain plug is installed using a new aluminium
washer and that it is tightened to the correct torque.
(See Table 2. Torque Settings ( B-94).)

B - 95 9803/4160-12 B - 95
 Section B - Body & Framework
Cooling Pack
436 from Serial No. 534200

Key Key
1 Cooling Pack Assembly 7 Side Mounting Brackets
2 Lifting Points 8 Cooling Pack Lower Mounting
3 Fan Cowl 9 Motor Frame Mounting Bolts
4 Fan Motor 10 Fan Securing Bolts
5 Fan Mounting Frame 11 Section Securing Bolts
6 Fan Guards 12 Fan Guard Securing Bolts

Fig 17.

B - 96 9803/4160-12 B - 96
 Section B - Body & Framework
Cooling Pack
426 from M1231500, 436 from M1305000

426 from M1231500, 436 from M1305000

Introduction
The 426/436 models are being fitted with a new type
cooling pack from the above serial numbers. As with its
predecessor it has individual sections for Charge Air
Cooling, Engine Coolant, Transmission Fluid and
Hydraulic Oil Cooling, though only the engine cooling fan 
is piped into the hydraulic oil cooler.

As with the preceding model, the pack sections are

positioned vertically. When viewed from the rear of the
machine the sections from left to right are, Charged Air
Cooling, Transmission Fluid Cooling, Engine Coolant
Radiator and Hydraulic oil cooler.

The sections as with the earlier type, can be replaced

individually by unbolting them from their top and bottom
mounting plates, though in order for a section to be
replaced, the whole cooling pack will need to be removed
from the machine.

Removal

1 Remove the rear bodywork as detailed in Removal
and Replacement of the Rear Bodywork ( B-73).


!MWARNING
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the 
system should be disconnected until the system has
been discharged by a refrigeration engineer or a Fig 18.
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant. 4 Lift the condenser forwards away from the cooling
pack and place securely inside the chassis.
4-3-4-1_2

Important: Do not undo the hoses to the air conditioning 5 Disconnect the lower charge air cooler hose, plug the
condenser. If the hoses are of insufficient length to allow open port and cap the hose to prevent the ingress of
the condenser to be safely stowed and must therefore be dirt or debris.
undone, then the system will need to be discharged by a
suitably qualified technician/refrigeration engineer. 6 Disconnect the hoses to the transmission cooler. Plug
the open ports and cap the hoses to prevent fluid loss
2 Release the catch on the left-hand side of the cooling and the ingress of dirt or debris.
pack holding the air conditioning condenser in the
closed position. 7 Remove the lower coolant hose being careful to
collect any coolant still in the hoses.
3 Remove the two bolts 18A on the right-hand side of
the cooling pack holding the air conditioning 8 Disconnect the hoses to the hydraulic cooler. Plug the
condenser 18B to the cooling pack 18C. open ports and cap the hoses to prevent fluid loss and
the ingress of dirt or debris.

B - 97 9803/4160-12 B - 97
 Section B - Body & Framework
Cooling Pack
426 from M1231500, 436 from M1305000
Note: Do not lift the cooling pack by any points other than
the designated lifting eyes, to do so could cause damage
to the cooling pack.

9 Attach a suitable sling to the lifting eyes incorporated

into the top of the cooling pack and attach to a
overhead crane.

10 Remove the lower cooing pack to chassis mounting

bolts.

11 Take the weight of the cooling pack on the crane.

Remove the upper mounting bolts 19A and rubber
mountings.

Fig 19.

12 Using the crane slowly lift the cooling pack from the
machine and stow safely on the ground.

B - 98 9803/4160-12 B - 98
 Section B - Body & Framework
Cooling Pack
426 from M1231500, 436 from M1305000
Replacement

Replacement is the reverse of removal but note the

following:

1 All hydraulic hose sealing O-rings must be replaced.

Do not over tighten the Allen bolts 20A securing the
hose flanges to the cooling pack. See Table 3.
Torque Settings ( B-99).

2 The correct concentration of coolant antifreeze is to

be added to the cooling system. A 50% antifreeze
mixture should be used even if frost protection is not
Fig 20.
needed. This gives protection against corrosion and
raises the coolants boiling point.

3 To provide sufficient corrosion protection,

Supplemental Coolant Additive (SCA) must be added
to the coolant mixture. The coolant filter provides the
required amount of SCA, provided it is replaced at
regular intervals. If the drained coolant is to be reused
then no action need be taken other than renewing the
coolant filter at its scheduled time. If however the
coolant is to be replaced with a fresh coolant mixture,
it is advisable to renew the coolant filter

Note: It is recommended that the cooling system be filled

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

!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1

4 When refitting the batteries, make sure they are

connected in the correct manner by connecting the
earth lead last.

Table 3. Torque Settings

Item Nm kgf m lbf ft
A (1) 25 2.5 18
Coolant drain 55 5.6 40
plug

(1) Allen Bolt

B - 99 9803/4160-12 B - 99
 Section B - Body & Framework
Cooling Pack
426 from M1231500, 436 from M1305000

Page left intentionally blank

B - 100 9803/4160-12 B - 100

Section C

Electrics
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-14



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section C - Electrics

Page left intentionally blank

C-0 9803/4160-14 C-0

 Section C - Electrics

Contents Page No.

Technical Data
General Electrical Data ........................................................................... C - 1
Light Bulbs ......................................................................................... C - 1
Fuses and Relays ................................................................................... C - 2
426 to M531064, 436 to M533069 .................................................... C - 2
426 from M531065, 436 from M533070 ............................................ C - 4
426 from M531300, 436 from M533300 ............................................ C - 6
446 from 540000 ............................................................................... C - 7
426 from M532100, 436 from M533692 ............................................ C - 8
426 from M532429, 436 from 534089 ............................................. C - 11
426 from M532847, 436 from M534468 .......................................... C - 14
426 from M1231500, 436 from M1305000 ...................................... C - 17
426 from M1295000, 436 from M1410000 ...................................... C - 20

Service Procedures
Using a Multimeter ................................................................................ C - 27
Measuring DC Voltage .................................................................... C - 28
Measuring Resistance ..................................................................... C - 28
Measuring Continuity ....................................................................... C - 29
Measuring Frequency ...................................................................... C - 29
Testing a Diode or a Diode Wire ...................................................... C - 30
Battery .................................................................................................. C - 31
Maintenance .................................................................................... C - 31
First Aid - Electrolyte ....................................................................... C - 31
Testing ............................................................................................. C - 32
Specific Gravity Testing ................................................................... C - 33
Alternator .............................................................................................. C - 34
General Description ......................................................................... C - 34
Service Precautions ........................................................................ C - 34
Charging Circuit Test ....................................................................... C - 34
Alternator Charging Test .................................................................. C - 35
Starter Motor ......................................................................................... C - 37
Starting Circuit Test ......................................................................... C - 37
Electronic Monitoring System (EMS) .................................................... C - 39
HC11 Display Panel ........................................................................ C - 39
C164 Display Panel ......................................................................... C - 46
24 - 12 Volt Power Distribution Board ............................................. C - 53

Fault Finding
Introduction to Fault - Finding Techniques ............................................ C - 55
Harness Routing .............................................................................. C - 55
Example of Wire Tracing ................................................................. C - 58
Component Testing ......................................................................... C - 59

Schematic Circuits
426 to 531064, 436 to 533069 ............................................................. C - 61
426 from 531065, 436 from 533070 ..................................................... C - 64
426 from 531300, 436 from 533300 ..................................................... C - 68
446 from 540000 .................................................................................. C - 72
426/436 from March ‘98 ........................................................................ C - 76
446 from March ‘98 ............................................................................... C - 84
426 from 532100, 436 from 533692 ..................................................... C - 92
426 from 532847, 436 from 534468 ................................................... C - 106
Auxiliary Circuits (426 from 532847, 436 from 534468) ...................... C - 111
436 Machines - Italian Military Only .................................................... C - 117

C-i C-i
 Section C - Electrics
Contents

Contents Page No.

426 from M1231500, 436 from M1305000 ......................................... C - 125
Instrumentation .............................................................................. C - 127
ZF Computer and Gearbox Controller ........................................... C - 129
Front Wipe, Rear Wipe, Heater/AC and Heated Rear Screen ...... C - 131
Front and Rear Worklights and Beacon ........................................ C - 133
Roadlights ..................................................................................... C - 135
Radio, Cigar Lighter, CCTV and Tow Hitch ................................... C - 138
ESOS, Heated Mirrors, Heated and Suspension Seat,
.............................................. Reverse Fan and Emergency Steer C - 140
12Volt Trailer Electrics and Loader Functions ............................... C - 142
Loader Auxiliaries (Proportional) ................................................... C - 144
Earthing - Cab and Cab Roof ........................................................ C - 146
Earthing - Front and Rear Chassis ................................................ C - 149
426 from M1295000, 436 from M1410000 ......................................... C - 151
Primary Fuses, Ignition Switch and Ignition Relays ...................... C - 151
Instrumentation .............................................................................. C - 153
ZF Computer and Gearbox Controller ........................................... C - 155
Tier 3 Engine ECU ......................................................................... C - 157
Front Wipe, Rear Wipe, Heater/AC ............................................... C - 159
Front and Rear Worklights and Beacon ........................................ C - 161
Roadlights ..................................................................................... C - 163
Radio, Cigar Lighter, CCTV and Tow Hitch ................................... C - 165
ESOS, Heated Mirrors, Heated and Suspension Seat,
.............................................. Reverse Fan and Emergency Steer C - 167
12Volt Trailer Electrics and Loader Functions ............................... C - 169
Loader Auxiliaries (Proportional) ................................................... C - 171
Earthing ......................................................................................... C - 173

Harness and Wire Number Identification

Wire and Harness Number Identification ............................................ C - 177
Introduction .................................................................................... C - 177
Wire Numbers and Functions ........................................................ C - 178
Connector Location and Identification ................................................ C - 179
426 from M531064, 436 from M533069 ........................................ C - 179
426 from M531300, 436 from 533300, 426 from 540000 .............. C - 182

C - ii C - ii
 Section C - Electrics
Contents

Contents Page No.

Harness Drawings .............................................................................. C - 185
Front Chassis Harness A & B -
.......................................426 from M531064, 436 from M 533069 C - 185
Rear Cab Harness A & B -
.......................................426 from M531064, 436 from M 533069 C - 186
Rear Chassis Harness A -
.......................................426 from M531064, 436 from M 533069 C - 187
Rear Chassis Harness B -
.......................................426 from M531064, 436 from M 533069 C - 188
Side Console Harness A -
.......................................426 from M531064, 436 from M 533069 C - 189
Side Console Harness B -
.......................................426 from M531064, 436 from M 533069 C - 190
Cab Roof Harness A & B -
........................................426 from M531064, 436 from M533069 C - 191
Front Chassis (HT) Harness -
........426 from M531300, 436 from M533300, 446 form M540000 C - 192
Front Chassis (ZX) Harness -
........426 from M531300, 436 from M533300, 446 from M540000 C - 193
Rear Chassis Harness - 426 from M531300, 436 from M533300 . C - 194
Rear Chassis Harness - 426 from M531300, 436 from M533300 . C - 195
Rear Chassis Harness - 446 from M540000 ................................. C - 196
Rear Chassis Harness - 446 from M540000 ................................. C - 197
Rear Chassis Harness - 426 from M531516, 436 from M533478 . C - 198
Rear Chassis Harness - 426 from M531516, 436 from M533478 . C - 199
Side Console Harness - 426 from M531516, 436 from M533478 . C - 200
Side Console Harness - 426 from M531516, 436 from M533478 . C - 201
Side Console Harness - 426 from M531516, 436 from M533478 . C - 202
Rear Cab Harness - 426 from M531516, 436 from M533478 ....... C - 203
Cab Roof Harness - 426 from M531516, 436 from M533478 ....... C - 204
Controller Harness - 426 from M531516, 436 from M533478 ....... C - 205
Rear Grille Harness - 426 from M531516, 436 from M533478 ..... C - 206
Under Bonnet Harness - 426 from M531516, 436 from M533478 C - 207
Front Chassis Harness HT -
........................................426 from M532100, 436 from M533692 C - 208
Front Chassis Harness ZX -
........................................426 from M532100, 436 from M533692 C - 209
Rear Chassis Harness - 426 from M532100, 436 from M533692 . C - 210
Side Console Harness - 426 from M532100, 436 from M533692 . C - 211
Side Console Harness - 426 from M532100, 436 from M533692 . C - 212
Side Console Harness -
........................................426 from M532100, 436 from M533692 C - 213
Side Console Harness - Smoothshift ............................................ C - 214
Side Console Harness - Smoothshift ............................................ C - 215
Side Console Harness - Smoothshift ............................................ C - 216
Side Console Harness - Smoothshift ............................................ C - 217
Rear Cab Harness - 426 from M532100, 436 from M533692 ....... C - 218
Cab Roof Harness - 426 from M532100, 436 from M533692 ....... C - 219
Engine Harness - 426 from M532100, 436 from M533692 ........... C - 220
Transmission Harness - 426 from M532100, 436 from M533692 . C - 221
Canopy Harness - 426 from M532100, 436 from M533692 .......... C - 222
Canopy Harness - 426 from M532100, 436 from M533692 .......... C - 223
Canopy Harness - 426 from M532100, 436 from M533692 .......... C - 224
Canopy Fuse Box Harness -
........................................426 from M532100, 436 from M533692 C - 225

C - iii C - iii
 Section C - Electrics
Contents

Contents Page No.

Canopy Fuse Box Harness -
........................................426 from M532100, 436 from M533692 C - 226
Canopy Fuse Box Harness -
........................................426 from M532100, 436 from M533692 C - 227
Proportional Solenoid Harness -
........................................426 from M532100, 436 from M533692 C - 228
Proportional Change Over Harness -
........................................426 from M532100, 436 from M533692 C - 229
Bang - Bang Solenoid Harness -
........................................426 from M532100, 436 from M533692 C - 230
Drawings and Interconnection ............................................................ C - 231
Harnesses 426 from M1231500, 436 from M1305000 .................. C - 231
Harnesses 426 from M1295000, 436 from M1410000 .................. C - 236
Drawings ....................................................................................... C - 245

Electronic Monitoring System

System Identification .......................................................................... C - 287
General .......................................................................................... C - 287
HC11 EMS .......................................................................................... C - 288
Description .................................................................................... C - 288
Connecting up the Laptop ............................................................. C - 300
Before Starting Service .................................................................. C - 301
On completion of Service .............................................................. C - 301
HC11 EMS - Software ........................................................................ C - 304
Installation ..................................................................................... C - 304
Installation from Techweb .............................................................. C - 304
Transfer New Program .................................................................. C - 304
Serial Number ............................................................................... C - 305
Log Data ........................................................................................ C - 305
Fault Limit Settings ........................................................................ C - 306
Connection of Interrogation Lead .................................................. C - 307
C164 EMS ......................................................................................... C - 308
General .......................................................................................... C - 308
EMS Tools ..................................................................................... C - 308
Flash Loader Program ................................................................... C - 309
Set-up Program ............................................................................. C - 310
Diagnostic Program ....................................................................... C - 313
Service History Program ............................................................... C - 314
Data Logger Program .................................................................... C - 315
Connecting the Interrogation Lead ................................................ C - 316

Alternator
S11524-7 Alternator ............................................................................ C - 317
Removal and Replacement ........................................................... C - 317
Dismantling and Assembling ......................................................... C - 318

C - iv C - iv
 Section C - Electrics
Contents

Contents Page No.

A5524 Alternator ............................................................................... C - 320
Dismantling .................................................................................... C - 320
Inspection, Testing and Repair ...................................................... C - 322
Rotor .............................................................................................. C - 322
Bearings ........................................................................................ C - 322
Slip ring end bearing - Removal and Replacement ....................... C - 322
Drive end bearing - Removal and Replacement ........................... C - 322
Slip ring end housing - Removing Rectifier ................................... C - 323
Refitting rectifier ............................................................................ C - 323
To remove and refit D+ and F- leads ............................................. C - 323
Brush holder assembly .................................................................. C - 323
Stator and housing ........................................................................ C - 323
Re-assembly ................................................................................. C - 323
Testing ........................................................................................... C - 325
Rectifier testing .............................................................................. C - 325
Testing ........................................................................................... C - 325
Regulator Check ............................................................................ C - 326

Starter Motor
426 and 436 Machines ....................................................................... C - 327
Removal and Replacement ........................................................... C - 327
Dismantling .................................................................................... C - 327
Servicing and Renewal .................................................................. C - 327
Assembly ....................................................................................... C - 327
446 Machines ..................................................................................... C - 329
Removal and Replacement ........................................................... C - 329
Dismantling .................................................................................... C - 329
Cleaning ........................................................................................ C - 329
Assembly ....................................................................................... C - 329
Setting the Drive Pinion Clearance (446) ...................................... C - 330
No Load Test (446) ........................................................................ C - 331

C-v C-v
 Section C - Electrics

Page left intentionally blank

C - vi C - vi
 Section C - Electrics

Technical Data
General Electrical Data

System Type 24 Volts, negative earth

Battery (Two 12 Volt batteries in series)
Cold Crank Amps for 1 minute to 1.4VPCat -18 °C (0 °F) 410 Amps
Reserve Capacity (minutes) for 25 Amp load 180
Alternator
426, 436 Butec A5524, 65 Amp maximum output
446 BOSCH 0120-488-206
Starter Motor
426, 436 S115 24-7
446 DELCO REMY 42-MT/400

Light Bulbs

Bulb Rating (Watts)

Headlights - main 75 W
Headlights - dip 70 W
Indicators 21 W
Indicator repeater 5W
Instruments 1.2 W
Work lights 70 W Halogen
Number plate light 10 W
Tail lights 5W
Front sidelights 5W
Interior lights 10 W
Stop lights 21 W
Beacon 70 W Halogen
Rear fog 21 W
Warning lights 1.2 W
Master Warning Light 5W

C-1 9803/4160-14 C-1

 Section C - Electrics
Technical Data
Fuses and Relays

Fuses and Relays

426 to M531064, 436 to M533069 Fuse Circuit Fuse

No. Rating
Fuses (Amps)
C2 Front Work Lights 25
The electrical circuits are protected by fuses. The fuses
are located in a fuse box underneath the oddments tray in C3 Transmission 10
the side console. If a fuse ruptures, find out why and rectify C4 Blank -
the fault before fitting a new one. C5 Horn and Front Wash/Wipe 10
C6 Blank -
!MCAUTION C7 Blank -
Fuses C8 Blank -
Always replace fuses with ones of correct ampere
rating to avoid electrical system damage. C9 Blank -
8-3-3-5
Relays

Fuse Circuit Fuse

A1 Neutral Start
No. Rating
(Amps) A2 Rear Work Lights/Reverse Lights
A1 Direction Indicators 5 A3 Reverse Alarm
A2 Right Sidelights and Gauge 10 A4 Hazard
Illumination A5 Seat Warning (Optional)
A3 Rear Fog Light 5 B1 Start
A4 Reverse Alarm/Dump Switch 10 B2 Front Work Lights
A5 Brake Lights, Loader Arm and Bucket 10 B3 Buzzer
Reset
B4 Transmission Timer
A6 Warning lights, Heater Fan and 20
Gauges
A7 Main Beam 10
A8 Blank -
A9 Blank -
B1 Hazard Warning Lights 10
B2 Dip Beam 10
B3 Rear Work Lights/Reversing Lights 10
B4 Rear Wash/Wipe 10
B5 Interior Light and Beacon 10
B6 Engine shut off system (ESOS) 5
B7 Air Conditioning (Optional) 10
B8 Blank -
B9 Blank -
C1 Left Sidelights 10

C-2 9803/4160-14 C-2

 Section C - Electrics
Technical Data
Fuses and Relays

 

 

 

 



Fig 1.

C-3 9803/4160-14 C-3

 Section C - Electrics
Technical Data
Fuses and Relays

426 from M531065, 436 from M533070 Fuse Circuit Fuse

No. Rating
Fuses (Amps)
C1 Left Sidelights and Number Plate 10
The electrical circuits are protected by fuses. The fuses Lights
are located in a fuse box underneath the oddments tray in
the side console. If a fuse ruptures, find out why and rectify C2 Front Work Lights 25
the fault before fitting a new one. C3 Transmission 10
C4 Blank -
!MCAUTION C5 Horn and Front Wash/Wipe 10
Fuses C6 Blank -
Always replace fuses with ones of correct ampere C7 Hydraulic Dump Valve 5
rating to avoid electrical system damage.
8-3-3-5
C8 Blank -
C9 Blank -

Fuse Circuit Fuse Relays

No. Rating
(Amps)
1 Hazard
A1 Direction Indicators 5
2 Blank
A2 Right Sidelights and Gauge 10
Illumination 3 Transmission timer
A3 Rear Fog Light 5 4 Neutral Start
A4 Reverse Alarm, Dump Switch, Anti- 10 5 Start
Stall Relay and Solenoid Valve 6 Blank
A5 Brake Lights, Loader Arm and Bucket 10
7 Blank
Reset
A6 8 Transmission Disconnect
Warning lights, Heater Fan, Gauges, 20
Cigar Lighter, Transmission 9 Front Work Lights
Disconnect Relay, Timer and 10 Anti-Stall
Hourmeter
11 Reverse Alarm
A7 Main Beam 10
12 Rear Work Lights/Reverse Lights
A8 Blank -
A9 Blank -
B1 Hazard Warning Lights and Clock 10
B2 Dip Beam 10
B3 Rear Work Lights/Reversing Lights 10
B4 Rear Wash/Wipe 10
B5 Interior Light, Beacon and Radio 10
(Optional)
B6 Engine shut off system (ESOS) 5
B7 Air Conditioning (Optional) 10
B8 Blank -
B9 Blank -

C-4 9803/4160-14 C-4

 Section C - Electrics
Technical Data
Fuses and Relays

  

  

  

  

Fig 2.

C-5 9803/4160-14 C-5

 Section C - Electrics
Technical Data
Fuses and Relays

426 from M531300, 436 from M533300 Fuse Circuit Fuse

No. Rating
(Amps)
C3 EMS and ZF Computer Feed 10
The electrical circuits are protected by fuses. The fuses
are located in a fuse box underneath the armrest in the C4 Blank -
side console. If a fuse ruptures, find out why and rectify the C5 Horn and Front Wash/Wipe 10
fault before fitting a new one. C6 Heater Blower and Cigar Lighter 20
C7 Hydraulic Dump Valve 5
!MCAUTION C8 ACCS 5
Fuses C9 Road Lights 15
Always replace fuses with ones of correct ampere
rating to avoid electrical system damage.
Relays
8-3-3-5

1 Direction Indicators
Fuse Circuit Fuse
2 Blank
No. Rating
(Amps) 3 Computer Feed
A1 Hazard Warning Lights and Direction 5 4 Engine Shut Down
Indicators 5 Start Inhibit
A2 Right Side/Tail Lights and Switch 5 6 ACCS (If fitted)
Illumination
7 Blank
A3 Rear Fog Light 5
8 Heater Fan
A4 Anti-stall (if fitted) 5
9 Front Work Lights
A5 Brake Lights, Float, Lift and Shovel 5
Reset 10 Anti-Stall (if fitted)
A6 Computer Feed Relay Solenoid 1 11 Reverse Alarm
A7 Main Beam 10 12 Rear Work Lights
A8 EMS Battery Feed 1
A9 Blank -
B1 Hazard Warning Lights (Battery Feed) 5
B2 Dip Beam 10
B3 Rear Work Lights and Reverse Alarm 10
B4 Rear Wash/Wipe 10
B5 Radio, Under Bonnet Lights, Interior 10
Light and Beacon
B6 Engine shut off system (ESOS) 5
B7 Air Conditioning 10
Fig 3.
B8 Thermostart 15
B9 Blank -
C1 Left Side/Tail Lights and No. Plate 5
Lights
C2 Front Work Lights 15

C-6 9803/4160-14 C-6

 Section C - Electrics
Technical Data
Fuses and Relays

446 from 540000 Fuse Circuit Fuse

No. Rating
(Amps)
C1 Left Side/Tail Lights and No. Plate 5
The electrical circuits are protected by fuses. The fuses Lights
are located in a fuse box underneath the armrest in the
side console. If a fuse ruptures, find out why and rectify the C2 Front Work Lights 15
fault before fitting a new one. C3 EMS and ZF Computer Feed 10
C4 Blank -
!MCAUTION C5 Horn and Front Wash/Wipe 10
Fuses C6 Heater Blower and Cigar Lighter 20
Always replace fuses with ones of correct ampere C7 Grid Heater Relay and Hydraulic Dump 5
rating to avoid electrical system damage. Valve
8-3-3-5
C8 ACCS 5
C9 Road Lights 15
Fuse Circuit Fuse
No. Rating Relays
(Amps)
A1 Hazard Warning Lights and Direction 5
1 Direction Indicators
Indicators
2 Intermittent Wipers
A2 Right Side/Tail Lights and Switch 5
Illumination 3 Computer Feed
A3 Rear Fog Lights 5 4 Engine Shut Down
A4 Blank - 5 Start Inhibit
A5 Brake Lights, Float, Lift and Shovel 5 6 ACCS
Reset 7 Blank
A6 Computer Feed Relay Solenoid 1
8 Heater Fan
A7 Main Beam 10 9 Front Work Lights
A8 EMS Battery Feed 1 10 Blank
A9 Blank -
11 Reverse Alarm
B1 Hazard Warning Lights (Battery Feed) 5
12 Rear Work Lights
B2 Dip Beam 10
B3 Rear Work Lights and Reverse Alarm 10
B4 Rear Wash/Wipe 10
B5 Radio, Under Bonnet Lights, Interior 10
Light and Beacon
B6 Engine shut off system (ESOS Hold 5
Coil)
B7 Air Conditioning 10
B8 Engine shut off system (ESOS Pull 30
Coil)
B9 Blank -
Fig 4.

C-7 9803/4160-14 C-7

 Section C - Electrics
Technical Data
Fuses and Relays

426 from M532100, 436 from M533692 Fuse Circuit Fuse

No. Rating
(Amps)
C3 Blank -
The electrical circuits are protected by fuses. The fuses
are located in a fuse box to the rear of the side console. If C4 Rear Wash/Wipe 7.5
a fuse ruptures, find out why and rectify the fault before C5 Front Wash/Wipe and Horn 10
fitting a new one. C6 Heated Seat/Mirrors and Air 10
Suspension Seat (Option)
!MCAUTION C7 Air Conditioning (Option) 5
Fuses C8 Heater Blower 15
Always replace fuses with ones of correct ampere
C9 Direction Indicators 5
rating to avoid electrical system damage.
8-3-3-5 C10 Heated Rear Screen 15
D1 EMS (Ignition Feed) 3
Fuse Circuit Fuse D2 ZF Computer (Ignition Feed) 7.5
No. Rating D3 CCTV (Option) 5
(Amps)
D4 Blank -
A1 Rear Work Lights 10
D5 ESOS and Cold Start Advance 5
A2 Road Lights 15
D6 Reverse Lights and Alarm 5
A3 Front Work Lights 20
D7 In-cab 24/12 Volt Converter (Option) 10
A4 Dipped Beam 10
D8 Blank -
A5 Main Beam 10
D9 Brake Lights 7.5
A6 Rear Fog Lights 5
D10 Float, Lift and Shovel Reset and 4th 7.5
A7 Blank - Spool
A8 Thermostart 30
A9 Dump Relay 3 (1) Not fitted if in-cab 24/12 Volt converter fitted.
A10 Ignition Relays 3
B1 Right Side/Tail Lights and Switch 3
Illumination
B2 Left Side/Tail Lights and No. Plate 3
Lights
B3 12 Volt Trailer Electrics (Option) 10
B4 EMS (Battery Feed) 3
B5 ZF Computer (Battery Feed) 7.5
B6 Hazard Warning 10
B7 Beacon and Interior Light 7.5
B8 Radio (24 Volt) 10
B9 Headlight Flash 15
Fig 5.
B10 Side Lights 5
C1 Starter Relay Solenoid 3 Note: to gain access to the underside of the fuse/relay
panel. Remove the securing screw and unhook the rear of
C2 Cigar Lighter (24 Volt)(1) 10

C-8 9803/4160-14 C-8

 Section C - Electrics
Technical Data
Fuses and Relays
the panel. Manipulate the panel until it is clear. Make sure Fuse Circuits Fuse
the panel is refitted securely. No. Rating
(Amps)
Primary Fuses
EMS (Ignition Feed)
The primary fuses are located in a fuse box attached to the ZF Computer (Ignition Feed)
battery positive terminal. If a fuse ruptures, find out why Rear Wash/Wipe
and rectify the fault before fitting a new one.
Front Wash/Wipe and Horn
Cigar Lighter (24 Volt)
Fuse Circuits Fuse
No. Rating ESOS and Cold Start Advance
(Amps) Reverse Alarm/Lights
PF1 40 Headlight Flash
Front Work Lights Brake Lights
Rear Work Lights Shovel and Arm Reset
Main Beam CCTV
Dip Beam In-cab 24/12 Volt Converter
Fog Lights
PF2 40
RH Side/Tail Lights and Switch
Illumination
LH Side/Tail Lights and No. Plate
Lights
Headlight Flash
Radio (24 Volt)
Beacon and Interior Light Fig 6.
Hazard Warning
Relays
EMS (Battery Feed)
ZF Computer (Battery Feed)
12 Volt Trailer Electrics 1 Heated Rear Screen

PF3 426 - 40 2 Ignition 2

436 - 50 3 Flasher

Starter Solenoid 4 Front Work Lights

Thermostart 5 Lights

Heater Blower 6 Reverse Alarm/Lights

Air Conditioning 7 Dump

Direction Indicators 8 Air Conditioning

Heated Seat, Mirrors and Air 9 Blank

suspension Seat 10 ESOS
Heated Rear Screen 11 Ignition 1
Ignition Relays 12 Ignition 3
PF4 50 13 Wash/Wipe Interval Timer

C-9 9803/4160-14 C-9

 Section C - Electrics
Technical Data
Fuses and Relays

14 Start
15 Blank

Diagnostic Connectors

X ZF Transmission
Y EMS

Fig 7.

C - 10 9803/4160-14 C - 10
 Section C - Electrics
Technical Data
Fuses and Relays

426 from M532429, 436 from 534089 Fuse Circuit Fuse

No. Rating
(Amps)
C3 Blank -
The electrical circuits are protected by fuses. The fuses
are located in a fuse box to the rear of the side console. If C4 Rear Wash/Wipe 7.5
a fuse ruptures, find out why and rectify the fault before C5 Front Wash/Wipe and Horn 10
fitting a new one. C6 Heated Seat/Mirrors and Air 10
Suspension Seat (Option)
!MCAUTION C7 Air Conditioning (Option) 5
Fuses C8 Heater Blower 15
Always replace fuses with ones of correct ampere C9 Direction Indicators 5
rating to avoid electrical system damage.
8-3-3-5
C10 Heated Rear Screen 15
D1 EMS (Ignition Feed) 3
D2 ZF Computer (Ignition Feed) 7.5
Fuse Circuit Fuse
No. Rating D3 CCTV (Option) 5
(Amps) D4 Blank -
A1 Rear Work Lights 10 D5 ESOS and Cold Start Advance 5
A2 Road Lights 15 D6 Reverse Lights and Alarm 5
A3 Front Work Lights 20 D7 In-cab 24/12 Volt Converter (Option) 10
A4 Dipped Beam 10 D8 Reversing Fan (Option) 5
A5 Main Beam 10 D9 Brake Lights 7.5
A6 Rear Fog Lights 5 D10 Float, Lift and Shovel Reset and 4th 7.5
A7 Grid Heater Relay (Tier II) 3 Spool
A8 Thermostart (Tier I) 30
(1) Not fitted if in-cab 24/12 Volt converter fitted.
A9 Dump Relay 3
A10 Ignition Relays 3
B1 Right Side/Tail Lights and Switch 3
Illumination
B2 Left Side/Tail Lights and No. Plate 3
Lights
B3 12 Volt Trailer Electrics (Option) 10
B4 EMS (Battery Feed) 3
B5 ZF Computer (Battery Feed) 7.5
B6 Hazard Warning 10
B7 Beacon and Interior Light 7.5
B8 Radio (24 Volt) 10
B9 Headlight Flash 15
B10 Side Lights 5
C1 Starter Relay Solenoid 3
C2 Cigar Lighter (24 Volt) (1) 10

C - 11 9803/4160-14 C - 11
 Section C - Electrics
Technical Data
Fuses and Relays

Fuse Circuits Fuse

No. Rating
(Amps)
PF2 40
RH Side/Tail Lights and Switch
Illumination
LH Side/Tail Lights and No. Plate
Lights
Headlight Flash
Radio (24 Volt)
Beacon and Interior Light
Hazard Warning
EMS (Battery Feed)
ZF Computer (Battery Feed)
12 Volt Trailer Electrics
PF3 426 - 60
436 - 50
436 Tier II - 40
Starter Solenoid
Thermostart
Heater Blower
Air Conditioning
Direction Indicators
Heated Seat, Mirrors and Air
suspension Seat
Heated Rear Screen
Fig 8.
Ignition Relays
Primary Fuses PF4 50
EMS (Ignition Feed)
The primary fuses are located in a fuse box attached to the
battery positive terminal. If a fuse ruptures, find out why ZF Computer (Ignition Feed)
and rectify the fault before fitting a new one. Rear Wash/Wipe
Front Wash/Wipe and Horn
Fuse Circuits Fuse Cigar Lighter (24 Volt)
No. Rating
(Amps) ESOS and Cold Start Advance

PF1 50 Reverse Alarm/Lights

Front Work Lights Headlight Flash

Rear Work Lights Brake Lights

Main Beam Shovel and Arm Reset

Dip Beam CCTV

Fog Lights In-cab 24/12 Volt Converter

C - 12 9803/4160-14 C - 12
 Section C - Electrics
Technical Data
Fuses and Relays

Fig 9.

Relays

1 Blank
2 Air Conditioning
3 Dump
4 Ignition 3
5 Ignition 1
6 ESOS
7 Flasher
8 Ignition 2
9 Heated Rear Screen
10 Reverse Alarm/Lights
11 Lights
12 Front Work Lights
13 Start
14 Wash/Wipe Interval Time
15 Brake Lights Fig 11.
16 Reverse Fan (Option 436)

Diagnostic Connectors

X ZF Transmission
Y EMS

Fig 10.

C - 13 9803/4160-14 C - 13
 Section C - Electrics
Technical Data
Fuses and Relays

426 from M532847, 436 from M534468 Fuse Circuit Fuse

No. Rating
Fuses (Amps)
C3 Blank -
The electrical circuits are protected by fuses. The fuses
are located in a fuse box to the rear of the side console. If C4 Rear Wash/Wipe 7.5
a fuse ruptures, find out why and rectify the fault before C5 Front Wash/Wipe and Horn 10
fitting a new one. C6 Heated Seat/Mirrors and Air 10
Suspension Seat (Option)
!MCAUTION C7 Air Conditioning (Option) 5
Fuses C8 Heater Blower 15
Always replace fuses with ones of correct ampere C9 Direction Indicators 5
rating to avoid electrical system damage.
8-3-3-5
C10 Heated Rear Screen 15
D1 EMS (Ignition Feed) 3
D2 ZF Computer (Ignition Feed) 7.5
Fuse Circuit Fuse
No. Rating D3 CCTV (Option) 5
(Amps) D4 Emergency Steering 5
A1 Rear Work Lights 10 D5 ESOS and Cold Start Advance 5
A2 Road Lights 15 D6 Reverse Lights and Alarm 5
A3 Front Work Lights 20 D7 In-cab 24/12 Volt Converter (Option) 10
A4 Dipped Beam 10 D8 Reversing Fan (Option - 436 only) 5
A5 Main Beam 10 D9 Brake Lights 7.5
A6 Rear Fog Lights 5 D10 Float, Lift and Shovel Reset and 4th 7.5
A7 Grid Heater Relay (Tier II) 3 Spool
A8 Blank -
(1) Not fitted if in-cab 24/12 Volt converter fitted.
A9 Dump Relay 3
A10 Ignition Relays 3
B1 Right Side/Tail Lights and Switch 3
Illumination
B2 Left Side/Tail Lights and No. Plate 3
Lights
B3 12 Volt Trailer Electrics (Option) 10
B4 EMS (Battery Feed) 3
B5 ZF Computer (Battery Feed) 7.5
B6 Hazard Warning 10
B7 Beacon and Interior Light 7.5
B8 Radio (24 Volt) 10
B9 Headlight Flash 15
B10 Side Lights 5
C1 Starter Relay Solenoid 3
C2 Cigar Lighter (24 Volt) (1) 10

C - 14 9803/4160-14 C - 14
 Section C - Electrics
Technical Data
Fuses and Relays

Fuse Circuits Fuse

No. Rating
(Amps)
PF2 40
RH Side/Tail Lights and Switch
Illumination
LH Side/Tail Lights and No. Plate
Lights
Headlight Flash
Radio (24 Volt)
Beacon and Interior Light
Hazard Warning
EMS (Battery Feed)
ZF Computer (Battery Feed)
12 Volt Trailer Electrics
PF3 426 - 40
436 - 50
436 Tier II - 40
Starter Solenoid
Thermostart
Heater Blower
Air Conditioning
Direction Indicators
Heated Seat, Mirrors and Air
suspension Seat
Fig 12. Heated Rear Screen
Ignition Relays
Primary Fuses
PF4 50
The primary fuses are located in a fuse box attached to the EMS (Ignition Feed)
battery positive terminal. If a fuse ruptures, find out why
ZF Computer (Ignition Feed)
and rectify the fault before fitting a new one.
Rear Wash/Wipe
Fuse Circuits Fuse Front Wash/Wipe and Horn
No. Rating Cigar Lighter (24 Volt)
(Amps)
ESOS and Cold Start Advance
PF1 50
Reverse Alarm/Lights
Front Work Lights
Headlight Flash
Rear Work Lights
Brake Lights
Main Beam
Shovel and Arm Reset
Dip Beam
CCTV
Fog Lights
In-cab 24/12 Volt Converter

C - 15 9803/4160-14 C - 15
 Section C - Electrics
Technical Data
Fuses and Relays

Fuse Circuits Fuse

No. Rating
(Amps)
Emergency Steering 100
Mounted next to the emergency steering pump.
Fig 14.

Fig 13.

Relays

1 Emergency Steering
2 Air Conditioning
3 Dump
4 Ignition 3
5 Ignition 1
6 ESOS
7 Flasher
8 Ignition 2
9 Heated Rear Screen
10 Reverse Alarm/Lights
11 Lights
12 Front Work Lights
13 Start
14 Wash/Wipe Interval Time
15 Brake Lights Fig 15.
16 Reverse Fan (Option - 436 Only)

Diagnostic Connectors

X ZF Transmission
Y EMS

C - 16 9803/4160-14 C - 16
 Section C - Electrics
Technical Data
Fuses and Relays

426 from M1231500, 436 from M1305000 Fuse Circuit(s) Protected Rating
C1 Starter Relay 3A
!MCAUTION C2 Cigar Lighter (24 volt) 10A
Fuses Loader Auxiliaries, Quickhitch, Servo
Always replace fuses with ones of correct ampere C3 7.5A
Isolator
rating to avoid electrical system damage.
C4 Rear Wash/Wipe 7.5A
8-3-3-5
C5 Front Wash/Wipe, Horn 10A
The electrical circuits are protected by fuses. The fuses C6 Heater Motor 20A
are located in a fuse box (shown with the lid removed)
behind the drivers seat. C7 Air Conditioning Compressor 5A
C8 Heated Mirrors/Seat, Suspension Seat 20A
If a fuse ruptures, find out why and rectify the fault before C9 Direction Indicators 5A
fitting a new one.
C10 Trailer Electrics (12 volt) 10A
Secondary Fuses
Fuse Circuit(s) Protected Rating
Fuse Circuit(s) Protected Rating D1 EMS Ignition Feed 3A
A1 Front Work Lights Relay, Ign 1 Relay 20A ZF Computer Ignition Feed, SRS
D2 7.5A
A2 Additional Front Work Lights (2 Total) 10A Solenoid
A3 Rear Work Lights (2 Total) 10A D3 Reversing Camera 5A
A4 Additional Rear Work Lights (2 Total) 10A D4 Emergency Steer System 1A
A5 Roadlight Switch (Headlights) 15A D5 Shutdown relay, Immobiliser 5A
A6 Main Beam 10A D6 Reverse Alarm and Lights 5A
A7 Rear Fog Light 5A 24/12 volt Dropper (Radio, Cigar /
D7 10A
Lighter, Auxiliary)
A8 Grid Heater Relay 3A
D8 Reverse Fan 5A
A9 Blank -
D9 Brake lights, Tow Hitch Solenoids 7.5A
A10 Blank -
D10 Shovel and Arm Reset 7.5A

Fuse Circuit(s) Protected Rating

B1 RH Sidelights 3A
B2 LH Sidelights 3A
B3 Heated Rear Screen 15A
B4 EMS Battery Feed 3A
B5 ZF Computer Battery Feed 7.5A
B6 Hazard Indicators 10A
B7 Beacon/Interior Light 7.5A
B8 Radio (24 volt) 10A
B9 Headlight Flash 15A
B10 Ignition Relays/Roadlight Illumination 5A

C - 17 9803/4160-14 C - 17
 Section C - Electrics
Technical Data
Fuses and Relays
Relays
 
Relay Circuit
1 Ignition 1
2 Ignition 2
3 Brake Lights
4 Reverse Light
 
5 Engine Shutdown
6 Transmission Reverse
7 Emergency Steer
  
8 Air Conditioning
9 Transmission Dump
   
10 Ignition 3
11 Front Work Lights
12 Lights  
 
13 Flasher Unit
14 Heated Rear Screen
15 Neutral Start    
16 Blank
17 Blank

Diagnostic Connectors

X ZF Transmission
Y EMS

Fig 16.

C - 18 9803/4160-14 C - 18
 Section C - Electrics
Technical Data
Fuses and Relays
Primary Fuses Fuse Circuit(s) Protected Rating

The primary fuses are located in a fuse box mounted at the PF5 Rear Work Lights 40A
right side of the battery bay inside the rear grille. Roadlight Switch (Headlights)

If a fuse ruptures, find out why and rectify the fault before
fitting a new one. Fuse Circuit(s) Protected Rating
PF6 Heater Motor 60A
Fuse Circuit(s) Protected Rating Air Conditioning Compressor
PF1 Front Work Lights 60A
Ignition 1 Fuse Circuit(s) Protected Rating
EMS (Ignition Feed) PF7 RH Sidelights 30A
ZF Computer (Ignition Feed) LH Sidelights
ACCS Heated Rear Screen
Reversing Camera EMS (Battery Feed)
Emergency Steer System ZF Computer (Battery Feed)
ESOS and Immobiliser
Reverse Alarm and Lights Fuse Circuit(s) Protected Rating
Blank PF8 Blank -

Fuse Circuit(s) Protected Rating


PF2 Hazard Indicators 40A  
Beacon and Interior Light  
Radio (24 volt)
Headlight Flash 
 

Fuse Circuit(s) Protected Rating  

PF3 Ignition 60A
Fig 17.
Roadlight Illumination

Fuse Circuit(s) Protected Rating

PF4 Cigar Lighter 60A
Loader Auxiliaries, Quickhitch and
Servo Isolator
Rear Wash/Wipe
Front Wash/Wipe and Horn
24/12 volt Dropper (Radio, Cigar Lighter
and Aux.)
Reverse Fan
Brake Lights and Tow Hitch Solenoids
Shovel and Arm Reset

C - 19 9803/4160-14 C - 19
 Section C - Electrics
Technical Data
Fuses and Relays

426 from M1295000, 436 from M1410000 Fuse Circuit(s) Protected Rating
C1 Starter Relay 3A
!MCAUTION C2 Cigar Lighter (24 volt) 10A
Fuses Loader Auxiliaries, Quickhitch, Servo
Always replace fuses with ones of correct ampere C3 7.5A
Isolator
rating to avoid electrical system damage.
C4 Rear Wash/Wipe 7.5A
8-3-3-5
C5 Front Wash/Wipe, Horn 10A
The electrical circuits are protected by fuses. The fuses C6 Heater Motor 20A
are located in a fuse box (shown with the lid removed)
behind the drivers seat. C7 Air Conditioning Compressor 5A
C8 Heated Mirrors/Seat, Suspension Seat 20A
If a fuse ruptures, find out why and rectify the fault before C9 Direction Indicators 5A
fitting a new one.
C10 Trailer Electrics (12 volt) 10A
Secondary Fuses
Fuse Circuit(s) Protected Rating
Fuse Circuit(s) Protected Rating D1 EMS Ignition Feed 3A
A1 Front Work Lights Relay, Ign 1 Relay 20A ZF Computer Ignition Feed, SRS
D2 7.5A
A2 Additional Front Work Lights (2 Total) 10A Solenoid
A3 Rear Work Lights (2 Total) 10A D3 Reversing Camera 5A
A4 Additional Rear Work Lights (2 Total) 10A D4 Emergency Steer System 1A
A5 Roadlight Switch (Headlights) 15A D5 Shutdown relay, Immobiliser 5A
A6 Main Beam 10A D6 Reverse Alarm and Lights 5A
A7 Rear Fog Light 5A 24/12 volt Dropper (Radio, Cigar /
D7 10A
Lighter, Auxiliary)
A8 Grid Heater Relay 3A
D8 Reverse Fan 5A
A9 Blank -
D9 Brakelights, Tow Hitch Solenoids 7.5A
A10 Blank -
D10 Shovel and Arm Reset 7.5A

Fuse Circuit(s) Protected Rating

B1 RH Sidelights 3A
B2 LH Sidelights 3A
B3 Heated Rear Screen 15A
B4 EMS Battery Feed 3A
B5 ZF Computer Battery Feed 7.5A
B6 Hazard Indicators 10A
B7 Beacon/Interior Light 7.5A
B8 Radio (24 volt) 10A
B9 Headlight Flash 15A
B10 Ignition Relays/Roadlight Illumination 5A

C - 20 9803/4160-14 C - 20
 Section C - Electrics
Technical Data
Fuses and Relays
Relays
 
Relay Circuit
1 Ignition 1
2 Ignition 2
3 Brake Lights
4 Reverse Light
 
5 Engine Shutdown
6 Transmission Reverse
7 Emergency Steer
  
8 Air Conditioning
9 Transmission Dump
   
10 Ignition 3
11 Front Work Lights
12 Lights  
 
13 Flasher Unit
14 Heated Rear Screen
15 Neutral Start    
16 Blank
17 Blank

Diagnostic Connectors

X CAN (EMS, Engine ECU and Transmission ECU)

Y ZF Transmission

Fig 18.

C - 21 9803/4160-14 C - 21
 Section C - Electrics
Technical Data
Fuses and Relays
Primary Fuses Fuse Circuit(s) Protected Rating

The primary fuses are located in a fuse box mounted at the PF5 Rear Work Lights 40A
right side of the battery bay inside the rear grille. Roadlight Switch (Headlights)

If a fuse ruptures, find out why and rectify the fault before
fitting a new one. Fuse Circuit(s) Protected Rating
PF6 Heater Motor 60A
Fuse Circuit(s) Protected Rating Air Conditioning Compressor
PF1 Front Work Lights 60A
Ignition 1 Fuse Circuit(s) Protected Rating
EMS (Ignition Feed) PF7 RH Sidelights 30A
ZF Computer (Ignition Feed) LH Sidelights
ACCS Heated Rear Screen
Reversing Camera EMS (Battery Feed)
Emergency Steer System ZF Computer (Battery Feed)
ESOS and Immobiliser
Reverse Alarm and Lights Fuse Circuit(s) Protected Rating
Blank PF8 Engine ECU 30A

Fuse Circuit(s) Protected Rating


PF2 Hazard Indicators 40A  
Beacon and Interior Light  
Radio (24 volt)
Headlight Flash 
 

Fuse Circuit(s) Protected Rating  

PF3 Ignition 60A
Fig 19.
Roadlight Illumination
Secondary Fuses
Fuse Circuit(s) Protected Rating
PF4 Cigar Lighter 60A Fuse Circuit(s) Protected Rating

Loader Auxiliaries, Quickhitch and A1 Front Work Lights Relay, Ign 1 Relay 20A
Servo Isolator A2 Additional Front Work Lights (2 Total) 10A
Rear Wash/Wipe A3 Rear Work Lights (2 Total) 10A
Front Wash/Wipe and Horn A4 Additional Rear Work Lights (2 Total) 10A
24/12 volt Dropper (Radio, Cigar Lighter A5 Roadlight Switch (Headlights) 15A
and Aux.) A6 Main Beam 10A
Reverse Fan A7 Rear Fog Light 5A
Brake Lights and Tow Hitch Solenoids A8 Grid Heater Relay 3A
Shovel and Arm Reset A9 Blank -

C - 22 9803/4160-14 C - 22
 Section C - Electrics
Technical Data
Fuses and Relays

Fuse Circuit(s) Protected Rating Fuse Circuit(s) Protected Rating

A10 Blank - D10 Shovel and Arm Reset 7.5A

Fuse Circuit(s) Protected Rating

B1 RH Sidelights 3A
B2 LH Sidelights 3A
B3 Heated Rear Screen 15A
B4 EMS Battery Feed 3A
B5 ZF Computer Battery Feed 7.5A
B6 Hazard Indicators 10A
B7 Beacon/Interior Light 7.5A
B8 Radio (24 volt) 10A
B9 Headlight Flash 15A
B10 Ignition Relays/Roadlight Illumination 5A

Fuse Circuit(s) Protected Rating

C1 Starter Relay 3A
C2 Cigar Lighter (24 volt) 10A
Loader Auxiliaries, Quickhitch, Servo
C3 7.5A
Isolator
C4 Rear Wash/Wipe 7.5A
C5 Front Wash/Wipe, Horn 10A
C6 Heater Motor 20A
C7 Air Conditioning Compressor 5A
C8 Heated Mirrors/Seat, Suspension Seat 20A
C9 Direction Indicators 5A
C10 Trailer Electrics (12 volt) 10A

Fuse Circuit(s) Protected Rating

D1 EMS Ignition Feed 3A
ZF Computer Ignition Feed, SRS
D2 7.5A
Solenoid
D3 Reversing Camera 5A
D4 Emergency Steer System 1A
D5 Shutdown relay, Immobiliser 5A
D6 Reverse Alarm and Lights 5A
24/12 volt Dropper (Radio, Cigar /
D7 10A
Lighter, Auxiliary)
D8 Reverse Fan 5A
D9 Brake lights, Tow Hitch Solenoids 7.5A

C - 23 9803/4160-14 C - 23
 Section C - Electrics
Technical Data
Fuses and Relays
Relays
 
Relay Circuit
1 Ignition 1
2 Ignition 2
3 Brake Lights
4 Reverse Light
 
5 Engine Shutdown
6 Transmission Reverse
7 Emergency Steer
  
8 Air Conditioning
9 Transmission Dump
   
10 Ignition 3
11 Front Work Lights
12 Lights  
 
13 Flasher Unit
14 Heated Rear Screen
15 Neutral Start    
16 Blank
17 Blank

Diagnostic Connectors

X ZF Transmission
Y EMS

Fig 20.

C - 24 9803/4160-14 C - 24
 Section C - Electrics
Technical Data
Fuses and Relays
Primary Fuses Fuse Circuit(s) Protected Rating

The primary fuses are located in a fuse box mounted at the PF5 Rear Work Lights 40A
right side of the battery bay inside the rear grille. Roadlight Switch (Headlights)

If a fuse ruptures, find out why and rectify the fault before
fitting a new one. Fuse Circuit(s) Protected Rating
PF6 Heater Motor 60A
Fuse Circuit(s) Protected Rating Air Conditioning Compressor
PF1 Front Work Lights 60A
Ignition 1 Fuse Circuit(s) Protected Rating
EMS (Ignition Feed) PF7 RH Sidelights 30A
ZF Computer (Ignition Feed) LH Sidelights
ACCS Heated Rear Screen
Reversing Camera EMS (Battery Feed)
Emergency Steer System ZF Computer (Battery Feed)
ESOS and Immobiliser
Reverse Alarm and Lights Fuse Circuit(s) Protected Rating
Blank PF8 Blank -

Fuse Circuit(s) Protected Rating


PF2 Hazard Indicators 40A  
Beacon and Interior Light  
Radio (24 volt)
Headlight Flash 
 

Fuse Circuit(s) Protected Rating  

PF3 Ignition 60A
Fig 21.
Roadlight Illumination

Fuse Circuit(s) Protected Rating

PF4 Cigar Lighter 60A
Loader Auxiliaries, Quickhitch and
Servo Isolator
Rear Wash/Wipe
Front Wash/Wipe and Horn
24/12 volt Dropper (Radio, Cigar Lighter
and Aux.)
Reverse Fan
Brake Lights and Tow Hitch Solenoids
Shovel and Arm Reset

C - 25 9803/4160-14 C - 25
 Section C - Electrics
Technical Data
Fuses and Relays

Page left intentionally blank

C - 26 9803/4160-14 C - 26
 Section C - Electrics

Service Procedures
Using a Multimeter
TC-002

In order to obtain maximum benefit from the fault finding

information contained in Section C 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 the fault from
the symptoms displayed you will be directed to make
measurements using a multimeter.

These instructions are intended to cover the use of the

recommended multimeters.

Fig 2. AVO 2003

Fig 1. FLUKE 85

Fig 3. A Typical Analogue Meter

C - 27 9803/4160-14 C - 27
 Section C - Electrics
Service Procedures
Using a Multimeter
1 Make sure that the test leads are plugged into the Measuring Resistance
correct sockets. The black test lead should be
plugged into the black socket (sometimes, this socket 1 Make sure there is no power to the part of the circuit
is also marked by a "-", or "E" or marked as you are about to measure.
"COMMON" or "COM"). The red test lead should be
plugged into the red socket marked with "+", "V" or 2 Connect one probe at one end of the component or
" ". wire to be checked and the other probe at the other
end. It does not matter which way round the two
2 When making measurements ensure that the test probes are placed.
probes have a good clean contact with bare metal,
free from grease, dirt, and corrosion as these can 3 Select the correct range on the multimeter.
cause a false reading.
a On the FLUKE 85.
3 When measuring voltage: Make sure that the correct
range is selected, that is set the selector to a value i Turn the switch to position 1-C and check that
equal to or greater than that you are about to the W sign at the right hand side of the display
measure. e.g. If asked to measure 12 Volts, set the window is on. If the F sign is on instead, press
selector to the 12V range. If there is no 12V range, set the blue button 1-G to change the reading to
the selector to the next range higher, 20V for . Touch the meter lead probes together and
instance. If the meter is set to a range that is too low, press the REL3 key on the meter to eliminate
it may be damaged. e.g. setting to the 2V range to the lead resistance from the meter reading.
measure 12V.
b On the AV0 2003.
Measuring DC Voltage
i Move the right hand slider switch to position 2-
1 Select the correct range on the multimeter. B, and the left hand slider switch to the
appropriate Ohms ( ) range.
a On the FLUKE 85.
c On an analogue meter.
Turn the switch to position 1-B.
i Move the dial to the appropriate Ohms ( )
b On the AV0 2003.
range.
Move the right slider switch to position 2-A, and
the left hand slider switch to the appropriate
range.

c On an analogue meter.

Turn the dial to the appropriate DC Volts range.

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.

C - 28 9803/4160-14 C - 28
 Section C - Electrics
Service Procedures
Using a Multimeter

Measuring Continuity Measuring Frequency

1 Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of
you are checking for continuity. measuring frequency, therefore a Fluke 85 digital
multimeter must be used.
2 Connect one probe to one end of the component or
wire to be checked and the other probe to the other 1 Insert the black plug into the COM socket on the
end. It does not matter which way round the two meter and attach the probe to the nearest suitable
probes are placed. 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 1-J.
a On the FLUKE 85.
3 Turn the selector switch to position 1-A and depress
Turn the switch to position 1-C and check that the 1-G repeatedly until 1-F is highlighted on the top row
beeper symbol appears at the left hand side of the of the display.
display window. If the F sign is on instead, press
the button labelled 1-F in the meter drawing. 4 Press button 1-H once.

If there is continuity in the circuit, the beeper will 5 Touch or connect the red probe to the frequency
sound. If there is no continuity (open circuit), the source to be measured. Press and hold button if an
beeper will not sound. average reading is required.

b On the AV0 2003.

Move the right hand slider switch to position 2-B,

and the left hand slider switch to position 2-C.

If there is continuity (i.e. very low resistance)

between two points the buzzer will sound.

c On an analogue meter.

Turn the dial to the lowest Ohms ( ) range.

If there is continuity (i.e. very low resistance)

between two points the needle will move across
fully (or almost fully) to the right hand side of the
scale.

C - 29 9803/4160-14 C - 29
 Section C - Electrics
Service Procedures
Using a Multimeter

Testing a Diode or a Diode Wire b On the AV0 2003.

A diode wire is a diode with male connector fitted on one i Move the right hand slider to position 2-A, and
end and a female connector fitted on the other end. The the left hand slider switch to position 2-C.
diode is sealed in heatshrink sleeving.
ii Connect the black probe to the end of the
1 To test a Diode or a Diode Wire diode marked with a band, or to the male
connector of the diode wire, the red probe
a On the FLUKE 85. should be connected to the other end of the
diode or diode wire. If the Avometer does not
i Turn the switch to position 1-D. buzz the diode is faulty.

ii Press the HOLD button and check that the H iii Connect the red probe to the end of the diode
sign appears at the top right hand side of the marked with a band, or to the male connector
display window. of the diode wire, the black probe should be
connected to the other end of the diode or
iii Connect the black probe to the end of the diode wire. If the Avometer does not read "1"
diode with a band or to the male connector of the diode is faulty.
the diode wire. Connect the red probe to the
other end of the diode or diode wire. If the c On an analogue meter.
beeper does not sound the diode or diode wire
is faulty. i Select the Ohms 1000s (1k) range.

iv Connect the red probe to the end of the diode Connect the black probe to the end of the
marked with a band, or to the male connector diode marked with a band, or to the male
of the diode wire, the black probe should be connector of the diode wire, the red probe
connected to the other end of the diode or should be connected to the other end of the
diode wire. If the beeper sounds or the meter diode or diode wire. The meter should read
does not read O.L., the diode or diode wire is 20-400 k , if it reads more than this the diode
faulty. is faulty.

v Press the HOLD button and check that the H ii Select the Ohms 100s range.
sign disappears from the right hand side of the
display window.

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 300-400 , if it reads less
than this the diode is faulty.

C - 30 9803/4160-14 C - 30
 Section C - Electrics
Service Procedures
Battery

Battery
TC-001_3

Maintenance !MWARNING
To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke
the following steps should be observed: when handling or working on the battery. Keep the
battery away from sparks and flames.
1 Make sure that the electrical connections are clean
and tight. Smear petroleum jelly on connectors to Battery electrolyte contains sulphuric acid. It can burn
prevent corrosion. you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
2 When applicable - never allow the electrolyte level to metallic items (watches, rings, zips etc) away from the
fall below the recommended level - 6 mm (1/4 in) battery terminals. Such items could short the
above the plates. Use only distilled water for topping terminals and burn you.
up.
Set all switches in the cab to OFF before
3 Keep the battery at least three quarters charged, disconnecting and connecting the battery. When
otherwise the plates may become sulphated disconnecting the battery, take off the earth (-) lead
(hardened) - this condition makes recharging the first.
battery very difficult.
Re-charge the battery away from the machine, in a well
Extra precautions must be taken when bench charging ventilated area. Switch the charging circuit off before
maintenance free batteries, they are more prone to connecting or disconnecting the battery. When you
damage by overcharging than the standard type of battery: have installed the battery in the machine, wait five
minutes before connecting it up.
– Never boost-charge a maintenance free battery.
When reconnecting, fit the positive (+) lead first.
– Never charge a maintenance free battery at a voltage
in excess of 15.8 Volts.
First Aid - Electrolyte
– Never continue to charge a maintenance free battery
after it begins to gas.
Do the following if electrolyte:

GETS INTO YOUR EYES

Immediately flush with water for 15 minutes, always get

medical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns

with a sterile dressing then get medical help.

5-3-4-3_1

C - 31 9803/4160-14 C - 31
 Section C - Electrics
Service Procedures
Battery

Testing 5 Set the CHECK/LOAD switch 4-A to LOAD and hold

down for 5-10 seconds until the meter reading
This test is to determine the electrical condition of the stabilises. The reading should be at least 9 volts.
battery and to give an indication of the remaining useful
`life'. Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
Before testing ensure that the battery is at least 75%
charged (SG of 1.23 to 1.25 for ambient temperature up to 6 Table 1. Fault Diagnosis ( C-32), if the
27°C). foregoing tests are unsatisfactory.

Ensure that the battery is completely disconnected from

the vehicle.

Connect up the battery tester as follows:

1 Set the CHECK/LOAD switch 4-A to OFF.

2 Set rocker switch 4-B to the battery voltage (12V).

3 Connect the red flying lead to the battery positive (+)

terminal and the black flying lead to the battery
negative (-) terminal.
Fig 4. Battery Tester
4 Set the CHECK/LOAD switch 4-A to CHECK to read
the battery no-load voltage which should be at least
12.4 volts.

Table 1. Fault Diagnosis

Battery Tester Readings Remedy
1 CHECK: 0 - 12.6 Volts Renew battery

LOAD: less than 6 Volts

2 CHECK: 6 - 12.4 Volts Recharge and re-test. If tests still unsatisfactory renew
battery.
LOAD: less than 9 Volts and falls steadily but remains
in yellow zone.
3 CHECK: less than 10 Volts Indicates battery has been over-discharged and unlikely to
recover. Renew battery.
LOAD: less than 3 Volts
4 CHECK: more than 11 Volts Charge battery which will probably recover.

LOAD: 6 - 10 Volts steady

C - 32 9803/4160-14 C - 32
 Section C - Electrics
Service Procedures
Battery

Specific Gravity Testing Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
The specific gravity of the electrolyte gives an idea of the indicates an internal fault on that particular cell.
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is If the electrolyte temperature is other than 15°C (60°F) a
15°C (60°F). If the battery has recently been on charge, 'correction factor' must be applied to the reading obtained.
wait approximately one hour (or slightly discharge the Add 0.07 per 10°C (18°F) if the temperature is higher than
battery) to dissipate the surface charge before testing. 15°C (60°F) and subtract the same if the temperature is
lower.

Table 2. Specific Gravity at 15°C (60°F)

Fully Charged Half Discharged Fully Discharged
Ambient temperature up to 27°C (80°F) 1.270 - 1.290 1.190 - 1.210 1.110 - 1.130
Ambient temperature above 27°C (80°F) 1.240 - 1.260 1.170 - 1.190 1.090 - 1.110

C - 33 9803/4160-14 C - 33
 Section C - Electrics
Service Procedures
Alternator

Alternator
TC-006

General Description Charging Circuit Test

The alternator is a three phase generator having a rotating 1 Ensure that all battery and alternator connections are
field winding and static power windings. in place, secure and making good metal - to - metal
contact, especially the 'earth' connections to chassis
When the start switch is turned on, current from the battery and engine.
flows by way of the 'No Charge' warning light to the field
winding. This creates a magnetic field which supplements 2 Adjust the alternator drive belt tension if necessary
the residual magnetism in the rotor poles. As the engine is and make sure that the battery is well charged.
started, the fan belt drives the rotor and alternating current
is generated in the power windings as they are cut by the 3 Turn the start switch to the ON position.
rotating magnetic field. Output is controlled by a solid state
regulator which varies the field current in accordance with 'Oil pressure' and 'No charge' warning lights should
electrical demand. glow. If any light fails, Check 1 ( C-34).

Servicing is restricted to periodic inspection of slip ring 4 Start the engine; all warning lights should extinguish
brushes. Bearings are 'sealed for life'. rapidly.

Service Precautions If the 'No charge' warning light remains ON, Check
2 ( C-35).
1 Ensure that the battery negative terminal is
connected to the earthing cable. If the oil pressure warning remains on stop engine
Immediately and investigate the engine lubrication
2 Never make or break connections to the battery or system.
alternator, or any part of the charging circuit whilst the
engine is running. Disregarding this instruction will Check 1
result in damage to the regulator or rectifying diodes.
With start switch 'ON' try the heater motor and screen
3 Main output cables are 'live' even when the engine is wiper.
not running. Take care not to earth connectors in the
moulded plug if it is removed from the alternator. If they operate normally, check the warning light bulb for
blown filament.
4 During arc welding on the machine, protect the
alternator by removing the moulded plug (or if Simultaneous failure of all items indicates a fault at the
separate output cables fitted, remove the cables). start switch. Check for cable disconnection before
condemning the switch itself.
5 If slave starting is necessary, connect the second
battery in parallel without disconnecting the vehicle If the 'No charge' warning bulb is in good order, withdraw
battery from the charging circuit. The slave battery the triple plug from the back of the alternator. Make a
may then be safely removed after a start has been temporary connection between the SMALL terminal in the
obtained. Take care to connect batteries positive to plug and earth as shown below. If the 'No charge' warning
positive, negative to negative. bulb still fails to light, check the cable for continuity. If the
bulb now lights, check the alternator for a defective
regulator. Alternator Charging Test ( C-35).

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 Section C - Electrics
Service Procedures
Alternator

Alternator Charging Test

Fig 5.

Check 2

Note: The following checks should be made using an

analogue (moving pointer) type meter.

1 Stop the engine and turn the starter switch to OFF.

2 Withdraw the alternator plug and connect the test Fig 7.

meter between the large terminals and 'earth'. With
the meter set to measure 12V DC, the meter should 1 Ensure that all battery and alternator connections are
show battery voltage. If the reading is zero, check the in place, secure and making good metal - to - metal
cables for continuity, particularly at the starter contact, especially the 'earth' connections to chassis
terminals. and engine.

2 Make sure that the alternator drive belt tension is

correctly adjusted.

3 If the battery is in a fully charged condition, switch on

the working lights for 3 minutes before commencing
the test. Alternatively, operate the starter for a few
moments with the engine shut off solenoid (ESOS)
fuse removed (See Fuse Identification).

4 Install a 100 amp open - type shunt between the

battery positive lead and the battery positive terminal.
Fig 6.
5 Connect a multimeter positive lead to machine side of
If the voltage is correct, check the alternator. the shunt and negative lead to battery side of the
Alternator Charging Test ( C-35). shunt.

6 Connect the leads to the meter and set the meter to

the relevant range as follows.

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 Section C - Electrics
Service Procedures
Alternator
11 Faults d, e, and f may be checked only by removing
AVO 2002 – Red lead to volts (middle) socket on
and dismantling the alternator for further testing.
meter.
– Black lead to negative on meter.
– RH slider to DC voltage.
– LH slider. Fig 7. ( C-35).
AVO 2003 – Red lead to amps socket (marked A) on
the meter.
– Black lead to negative on meter.
– RH slider to DC voltage
– LH slider to 200 Shunt
FLUKE 85 – Red lead to volts socket (marked V ) on
meter.
– Black lead to COM socket on meter.
– Set dial to mV.

7 Start the engine and run at maximum speed (see

Technical Data). Meter should show maximum
alternator output in Amps (see Technical Data).

Note: The meter reading should be taken as soon as

possible after starting the engine, as the charging current
will fall rapidly.

8 A zero reading indicates failure of the alternator and

may be caused by one of the following conditions.
These are listed in the order of probability.

a Defective suppression capacitor.

b Dirty slip rings or worn brushes.

c Defective regulator.

d Defective rectifier.

e Open or short - circuited field (rotor) windings.

f Open or short - circuited power (stator) windings.

9 To check for fault a, disconnect the capacitor and

repeat the charging test. Renew the capacitor if
necessary.

10 To check for faults b and c, 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
checked by substitution.

C - 36 9803/4160-14 C - 36
 Section C - Electrics
Service Procedures
Starter Motor

Starter Motor
TC-005

Starting Circuit Test than 0.5V below the reading obtained in Step 1.
Minimum permissible reading in 'start' position 9.0V.
Before carrying out the voltmeter tests, check the battery
condition and ensure that all connections are clean and If the reading is within this limit, continue to Step 3. If
tight. the reading is outside the limit, proceed to Step 4 and
Step 5.
To prevent the engine starting during the tests ensure that
the engine stop fuse is removed, (refer to Fuse
Identification page).

Check the readings in the following sequence using a

voltmeter. Unless otherwise stated, the readings must be
taken with the starter switch held in the 'start' position
('HS') and the transmission forward/reverse selector in
neutral.

Note: Do not operate the starter motor for more than 20

seconds at one time. Let the starter motor cool for at least
two minutes between starts.

1 Connect the voltmeter across the battery terminals.

Fig 8. ( C-37). Reading in 'start' position: 10.0V Fig 9.
approximately. Minimum permissible reading in 'start'
position 9.5V. 3 Connect the voltmeter between the solenoid terminal
10-C and a good earth. Minimum permissible reading
A low reading probably indicates a fault in the starter in 'start' position: 8.0V.
motor.

Fig 10.
Fig 8.
a If the reading is less than specified, connect the
2 Connect the voltmeter between the starter main voltmeter between the neutral start relay terminal
terminal 9-A and the commutator end bracket 9-B. In 11-D and earth. An increase in reading to 8.0V
the 'start' position, the reading should not be more indicates a fault in the wiring from the start relay to
the solenoid.

C - 37 9803/4160-14 C - 37
 Section C - Electrics
Service Procedures
Starter Motor
b If the reading between terminal 11-D and earth is 5 Connect the voltmeter between battery positive and
below 8.0V, connect the voltmeter between the starter main terminal 13-A. With the starter switch
terminal 11-E and earth. An increase in the 'off', the voltmeter should indicate battery voltage, but
reading to 8.0V indicates either a faulty start relay it should fall to practically zero when the switch is
or a fault in the feed from the transmission turned to the 'on' position, maximum permissible
selector switch to the relay solenoid. Check also reading 0.25V.
the solenoid earth connection.

If the reading between 11-E and earth is less than

8.0V, the fault must be in either the starter switch
or in the wiring between the solenoid, starter
switch, and the start relay.

Fig 13.

If the reading is above 0.25V, a high resistance is

present in the insulated lead or in the solenoid.
Connect the voltmeter between the battery positive
and solenoid connection 14-H. If the voltmeter now
reads zero with the switch closed, the fault is in the
Fig 11. solenoid.

4 Connect the voltmeter between battery negative and

starter earth connection 12-B. The reading in the
'start' position should be practically zero, maximum
permissible reading 0.25V.

If the reading is above 0.25V, a high resistance in the

earth lead or connections is indicated.

Fig 14.

6 Finally refit the engine stop fuse.

Fig 12.

C - 38 9803/4160-14 C - 38
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)

Electronic Monitoring System (EMS)

HC11 Display Panel Coolant Temperature

Illuminated if the temperature is high.
Ignition On

During the first second after switching on, all LCD Fuel Level
segments and warning lights are illuminated then the
software version is displayed on the top line. Flashes when only 10% of fuel is left in the
tank.
Pre-Start Mode
CAN-Bus Error
Illuminated if EMS receives a CAN bus error
from the ZF Computer.

The following warning lights will also illuminate and the

buzzer will sound:

Alternator No Charge

Brake Pressure Low (Unless accumulators

are still charged)

Parking Brake On
Fig 15.

The following are checked:

Engine Oil Pressure Low
Battery Voltage
Illuminated if the battery voltage is low.

Steering Pressure Low

Hydraulic Fluid Temperature
Illuminated if the temperature is high.

Transmission Oil Temperature

Illuminated if the temperature is high.

C - 39 9803/4160-14 C - 39
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Setting-up Start Inhibit

1 Turn on the power by turning the starter key to IGN. The following warnings will also cause the “START
INHIBIT” message to be displayed. The engine will not
2 Pressing the SETUP/SELECT button while in Pre- start until the fault is cleared.
Start Mode will allow the display to be set up as
follows:

Note: Use the up and down arrows to adjust display as

required.

1. CLK FORMAT
If Neutral is not selected, the panel will display the
The clock format (12/24 Hour) is shown in the top message “IN GEAR” and the buzzer will sound.
right corner.
If the parking brake is on and the transmission is not in
2. HOUR neutral, the message “PARK BRAKE” will also be
displayed.
3. AM/PM
START INHIBIT can be overridden by pushing the
With 12 Hour selected, AM or PM is selected and is MANUAL button once.
displayed in the top left corner.

4. MINUTE

5. YEAR

6. MONTH

7. DATE (Day)

8. LANGUAGE

English is the default language, there is one

alternative language. Certain languages are not
available.

9. Returns the display to Pre-Start Mode.

C - 40 9803/4160-14 C - 40
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Warning Lights Rear Fog Light On
Lights up when the rear fog light is switched
Visual Warning Only
on.

Direction Indicators
Emergency Steer Pump (If fitted)
Left or Right flashes with the direction
indicators. Both flash when Hazard Lights up when the emergency steering
Warning Lights are on. Use the indicators system is operating. ie. When the machine
to signal before turning. is moving.

Hazard Warning Parking Brake Engaged

Flashes with the hazard warning lights Lights up when the parking brake is
(even with the starter switch at O). Switch engaged.
the flashers on whenever your machine is a
possible hazard.

Side Lights On
Lights up when the side lights are switched
on.

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

Dip Beam On
Lights up when the headlight dipped lights
are switched on.

Front Work Lights On

Lights up when the front work lights are
switched on.

Rear Work Lights On

Lights up when the rear work lights are
switched on.

C - 41 9803/4160-14 C - 41
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Visual Warning plus Buzzer and Message Transmission Oil Temperature High

The message associated with these warnings will be Operates if the transmission oil
displayed on the top line of the display panel. temperature rises too high. “TRANS OIL
TEMP”

Battery Voltage Low

Water Temperature High
Lights up when the battery voltage is low.
“BATTERY LOW” Operates if the engine coolant temperature
rises too high. “COOLANT TEMP”

No Charge
Air Filter Blocked
Operates when the battery charging circuit
fails while the engine is running. The light Operates if the engine air filter clogs up.
should go out a few seconds after the “AIR FLTER BLKD”
engine is started. “ALTERNATOR”

Engine Oil Pressure Low

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

Brake System Pressure Low

Lights up when the brake system pressure
is low. “BRAKE FAILURE”

Transmission Oil Pressure Low

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

Note: Transmission Oil Pressure Low is not applicable

from Ser. No. 539250

Main Steer System (If fitted)

Lights up if the main hydraulic system
pressure fails. Stop the machine as soon
as it is safe to do so and rectify the fault.
“STEERING PRESS”

Hydraulic Fluid Temperature High

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

C - 42 9803/4160-14 C - 42
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Visual Warning and Message Segmented Displays

The message associated with this warning will be

Speedometer
displayed on the top line of the display panel.
Indicates the road speed. The road
speed is shown on the right side in
Service Required
miles per hour (mph) and kilometres
If lit, contact your JCB Distributor. (kph) on the left side.
“SERVICE REQD”

Note: The “SERVICE REQD” message is displayed in Fuel Gauge

Pre-Start mode only.
Indicates the level of fuel in the tank.
See Types of Fuel Section 3 for fuel
Note: If diagnostic option is fitted, the Service Required
to be used. Do not let the tank run dry,
warning and message will be displayed at pre-set intervals
or air will enter the fuel system.
and also if the diagnostic computer memory is full. The
Service Required is reset when data is down loaded by
your JCB distributor.
Note: The message “LOW FUEL” is displayed on the
Automatic Engine Shut Down panel when only 10% of fuel is left in the tank.

The following warnings will also initiate the automatic

engine shut down system. Water Temperature Gauge
Indicates the working temperature of
the engine coolant. Do not let the
indicator rise to the red danger zone of
the gauge.

Transmission Oil Temperature

Indicates the working temperature of
the transmission oil. Do not let the
indicator rise to the red danger zone of
the gauge.
A 30 second count down to engine shut down starts as
soon as the warning symbol is illuminated.

The count down time is displayed on the top line of the

display alternating with the appropriate warning dialogue. Hydraulic Fluid Temperature
Indicates the working temperature of
In an emergency, the MANUAL button will reset the the hydraulic fluid. Do not let the
counter to 30 seconds; this will allow the machine to be indicator rise to the red danger zone of
moved if necessary. the gauge.

Although there is no limit to the number of times the button

may be pressed, each press of the MANUAL button is
remembered in the diagnostic data logger.

Note: The ignition must be switched OFF after a shut down

to enable the system to reset.

C - 43 9803/4160-14 C - 43
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Master Warning Light Indicators (Engine Off)

The master warning light will illuminate to draw attention to

the display panel if any of the visual warnings operate.

Transmission Fault

In the event of the transmission developing a fault, the

EMS will display a fault code to aid diagnosis.

The fault code will be displayed on the top line of the

display panel. An example of a fault code is shown below.

ZFCB ERROR ??

A list of the fault codes is given in Section F -

Transmission - Fault Finding

Fig 16.

Indicators (Engine Running)

Fig 17.

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 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Using the Warning Light Test Button (Daily - to Note: Neutral (N) is displayed until the parking brake is
Serial Number 539249) disengaged when ranges 1 or 2 are selected.

1 Turn on the power by turning the starter key to IGN. !MCAUTION

2 Press the warning light test button while in Pre-Start Do not use the machine if any of the warning lights do
Mode. All the fault warning lights should illuminate. not illuminate. Have the fault rectified immediately.
4-2-1-3
3 If any of the fault warning lights fail to illuminate,
contact your JCB Distributor.

Warning Light Test (Daily - from Serial Number

539250)

1 Turn on the power by turning the starter key to IGN.

The following warnings will illuminate only when the test
2 All the fault warning lights should illuminate during the button is pressed:
start up cycle.

3 If any of the fault warning lights fail to illuminate,

contact your JCB Distributor.

Indicates that machine hours are displayed

top left of the display. Also, the following warnings will illuminate only when the
test button is pressed on machines with emergency steer:

Indicates that time is displayed top right of

the display.

!MCAUTION
All the warning lights should go out when the engine
is started. Rectify any faults immediately.
4-2-1-4

Indicates that transmission information is

displayed top left of the display.

Indicates that time is displayed top right of

the display.

The gear in use is indicated top left of the display.

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 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)

C164 Display Panel 4 Coolant Temperature

Ignition On Illuminated if the temperature is high.

During the first second after switching on, all LCD 5 CAN-Bus Error
segments and warning lights are illuminated then the
software version is displayed on the top line. Illuminated if EMS receives a CAN bus error from the
ZF Computer.
Pre-Start Mode
The following warning lights will also Illuminate and the
buzzer will sound:

Fig 20.

6 Engine Oil Pressure Low

7 Parking Brake On

8 Alternator No Charge
Fig 18.
9 Brake Pressure Low (unless accumulators are still
The following warning lights are checked:
charged)

10 Steering Pressure Low

Fig 19.

1 Battery Voltage

Illuminated if the battery voltage is low.

2 Hydraulic Fluid Temperature

Illuminated if the temperature is high.

3 Transmission Oil Temperature

Illuminated if the temperature is high.

C - 46 9803/4160-14 C - 46
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Setting Up Start Inhibit

1 Turn on the power by turning the starter key to IGN.

2 Pressing the SETUP/SELECT button while in Pre-

Start Mode will allow the display to be set up as
follows:

Note: Use the up and down arrows to adjust display as

required.

a CLK FORMAT Fig 21.

The clock format (12/24 Hour) is shown in the top The following warnings will also cause the "START
right corner. INHIBIT" message to be displayed. The engine will not
start until the fault is cleared or the process is complete.
b HOUR
1 Transmission Oil Temperature WARNING
c AM/PM
2 Wait to Start ACTIVE
With 12 Hour selected, AM or PM is selected and 3 Emergency Steer Pump WARNING
is displayed in the top left corner. 4 Coolant Temperature WARNING

d MINUTE
If Neutral is not selected, the panel will display the
message "IN GEAR" and the buzzer will sound.
e YEAR
If the parking brake is on and the transmission is not in
f MONTH
neutral, the message "PARK BRAKE" will also be
displayed.
g DATE (Day)
If there is a fault with the emergency steering, the message
h LANGUAGE
"STEER SW FAULT" will be displayed and the buzzer will
sound.
English is the default language, there is one
alternative language. Certain languages are not
START INHIBIT can be overridden by pushing the
available.
MANUAL button once.
i Returns the display to Pre-Start Mode.

C - 47 9803/4160-14 C - 47
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Warning Lights Visual Warnings plus Buzzer and Message

Visual Warnings Only The messages associated with these warnings will be
displayed on the top line of the display panel.

Fig 22.
Fig 23.
1 Direction Indicators
1 Battery Voltage Low
Left or Right flashes with the direction indicators. Both
flash when Hazard Warning Lights are on. Use the Lights up when the battery voltage is low.
indicators to signal before turning.
"BATTERY LOW"
2 Main Beam On
2 Engine Oil Pressure Low
Lights up when the headlight main beams are
switched on. Switch the main beams off for on- Operates if the engine oil pressure drops too far. The
coming traffic. light should go out when the engine is started.

3 Work Lights On "ENG OIL PRESS"

Lights up when the work lights are switched on. 3 Hydraulic Fluid Temperature High

4 Rear Fog Light On Operates if the hydraulic fluid temperature rises too
high.
Lights up when the rear fog light is switched on.
"HYD OIL TEMP"
5 Hazard Warning
4 Transmission Oil Temperature High
Flashes with the hazard warning lights (even with the
starter switch at O). Switch the flashers on whenever Operates if the transmission oil temperature rises too
your machine is a possible hazard. high.

6 Side Lights On "TRANS OIL TEMP"

Lights up when the side lights are switched on. 5 Emergency Steer Pump

7 Dip Beam On Lights up when the emergency steering system is

operating. ie. When the machine is moving.
Lights up when the headlight dipped lights are
switched on. Flashes when system fails to pressurise due to
system fault.
8 Parking Brake Engaged
"EM STEER FAULT".
Lights up when the parking brake is engaged.

C - 48 9803/4160-14 C - 48
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
6 No Charge Visual Warning and Message

Operates when the battery charging circuit fails while The messages associated with these warnings will be
the engine is running. The light should go out a few displayed on the top line of the display panel.
seconds after the engine is started.

"ALTERNATOR"

7 Brake System Pressure Low

Lights up when the brake system pressure is low.

"BRAKE FAILURE"

8 Main Steer System Fig 24.

Lights up if the main hydraulic system pressure fails. 1 Service Required

Stop the machine as soon as it is safe to do so and
rectify the fault. If lit, contact your JCB Dealer.

"STEERING PRESS" "SERVICE REQD"

9 Water Temperature High Note: The "SERVICE REQD" message is displayed in

Pre-Start Mode only.
Operates if the engine coolant temperature rises too
high. Note: If diagnostic option is fitted, the Service Requires
warning and message will be displayed at pre-set intervals
"COOLANT TEMP" and also if the diagnostic computer memory is full. The
Service Required is reset when data is down loaded by
10 Air Filter Blocked your JCB Dealer.

Operates if the engine air filter clogs up. 2 Engine Check/Error

"AIR FLTER BLKD" If lit, contact your JCB Dealer.

11 Water in Fuel "EXXX"

Operates if water is present in the fuel.

"WATER IN FUEL"

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 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Automatic Engine Shut Down Segmented Displays

The following warnings will also initiate the automatic

Speedometer
engine shut down system.
Indicates the road speed. The road speed
in miles per hour (mph) is shown in black
and kilometres (kph) are shown in red.

Fuel Gauge
Indicates the level of fuel in the tank.
Acceptable and Unacceptable
Fig 25. Fuels ( 1-108) for the fuel to be used.
1 Engine Oil Pressure Low The fuel system will be damaged if it
allowed to run out of fuel.
2 Transmission Oil Temperature High
3 Water in Fuel
4 Brake System Pressure Low Note: The message "LOW FUEL" is displayed on the
panel and the fuel gauge needle will flash when only 10%
5 Main Steer System
of fuel is left in the tank.
6 Coolant Temperature
7 Air Filter Blocked Note: When only 8% of fuel is left in the tank the engine
will also run rough as an indication to the operator.
A 30 second count down to engine shut down starts as
soon as the warning symbol is illuminated. Water Temperature
Indicates the working temperature of the
The count down time is displayed on the top line of the
engine coolant. Do not let the indicator rise
display alternating with the appropriate warning dialogue.
to the red danger zone of the gauge.
In an emergency, the MANUAL button will reset the
counter to 30 seconds; this will allow the machine to be
moved if necessary.

Although there is no limit to the number of times the button Transmission Oil Temperature
may be pressed, each press of the MANUAL button is Indicates the working temperature of the
remembered in the diagnostic data logger. transmission oil. Do not let the indicator
rise to the red danger zone of the gauge.
Note: The ignition switch must be switched OFF after a
shut down to enable the system to reset.

Hydraulic Fluid Temperature

Indicates the working temperature of the
hydraulic fluid. Do not let the indicator rise
into the red danger zone of the gauge.

C - 50 9803/4160-14 C - 50
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Indications (Engine Off) Indicates that Transmission information is
displayed top left of the display.

Indicates that time is displayed top right of

the display.

The gear in use is indicated top left of the display.

Note: Neutral (N) is displayed until the parking brake is

disengaged when ranges 1 or 2 are selected.

Fig 26.
Indicates that machine hours are
displayed top left of the display.

!MCAUTION
All the warning lights should go out when the engine
is started. Rectify any faults immediately.
4-2-1-4

Indications (Engine Running)

Fig 27.

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 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)
Master Warning Light Warning Light Test (Daily)

The master warning light will illuminate to draw attention to 1 Turn on the power by turning the starter key to IGN.
the display panel if any of the visual warnings display.
2 All the fault warning lights should illuminate during the
Transmission Fault start up cycle.

In the event of the transmission developing a fault, the 3 If any of the fault warning lights fail to illuminate,
EMS will display a fault code to aid diagnosis. contact your JCB Dealer.

A fault code will be displayed on the top line of the display

panel. An example of a fault code is shown below.
!MCAUTION
Do not use the machine if any of the warning lights do
not illuminate. Have the fault rectified immediately.
ZFCB ERROR ??
4-2-1-3

A list of the fault codes is given in the Service Manual.

ECU/EMS Communication Error

In the event of a breakdown in communication between the

engine ECU and the EMS.

The coolant temperature gauge needle

will flash.

The CAN Bus Error Light will Illuminate

If this situation occurs, check the fuses and relays on the

power distribution board 24 - 12 Volt Power
Distribution Board ( C-53).

If this does not resolve the problem, contact your JCB

Distributor.

C - 52 9803/4160-14 C - 52
 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)

24 - 12 Volt Power Distribution Board

If a fuse ruptures, find out why and rectify the fault before
fitting a new one.

Fuses and Relays

 


















Fig 28.

To gain access to the Fuses and Relays:

1 Remove the cab left side skirt.

Note: It may be necessary to disconnect the auxiliary fuel

tank breather pipe.

2 Remove and retain the 4 screws securing the cap.

Fig 29.

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 Section C - Electrics
Service Procedures
Electronic Monitoring System (EMS)

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C - 54 9803/4160-14 C - 54
 Section C - Electrics

Fault Finding


The fault-finding procedures detailed in this manual rely on Harness Routing

the correct use of a Fluke 85 digital multimeter for
measuring voltage, current, continuity and frequency. As a major aid to fault-finding we have detailed the point to
point wiring throughout the machine.
Instructions on the use of this meter are provided on
Using a Multimeter ( C-27) to Measuring The machines have individual harnesses as follows:
Frequency ( C-29) to enable the technician to use the
fault-finding tables to maximum effect. 1 front chassis harness

Fault diagnosis could involve the measurement of 2 rear chassis harness

continuity between certain points in a circuit. Whilst the
location of these points may look straightforward on the 3 side console harness
schematic diagram, the reality is somewhat different.
4 rear cab harness
The wiring in your machine is not laid out as shown in the
schematic diagram. For a variety of reasons associated 5 cab roof harness
with safety, reliability, ease of manufacturing and
servicing, the wires are shielded for most of their length, by 6 controller harness
a woven sleeve from which groups of wires (splices)
protrude in no apparent order. The sleeve or harness is 7 rear grille harness
tucked into inaccessible parts of the machine and
generally speaking, tracing a wire from source to 8 under bonnet light
destination can prove rather difficult.
Their approximate locations are shown in Connector
Location and Identification ( C-179). Each harness
has a number of associated connectors which connect to
specific machine functions within the harness area, such
as brake light, rear wipe etc. on the rear cab harness.
Some signals may need to be routed to functions in other
parts of the machine, for instance the side light switch wire
(803) in the cab must be routed to the sidelights via the
rear chassis harness and the front chassis harness. This
necessitates inter-harness connections and these are
identified in the diagram as TE/RK, FF/RA etc.

Fig 1. Schematic Diagram

C - 55 9803/4160-14 C - 55
 Section C - Electrics
Fault Finding
Introduction to Fault - Finding Techniques

Fig 2. Wiring Harness

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 Section C - Electrics
Fault Finding
Introduction to Fault - Finding Techniques

C - 57 9803/4160-14 C - 57
 Section C - Electrics
Fault Finding
Introduction to Fault - Finding Techniques

Example of Wire Tracing

This section contains information for each harness in the
form of a diagram showing the actual wire harness and
tables detailing the harness connections and wire
identification.

The diagram shows how wiring can be traced from point to

point using the harness information. With the knowledge
gained from this worked example it should be
straightforward to trace any wire through the machine.

Two way connector FE is connected to the front washer

motor. Wire 819 is the live wire and 600 AG, the chassis
connection. (All 600 series wires are chassis wires). The
FE table states that the destination of FE 1 is FH 4. FH 4
is the interface connector between the rear cab harness
and the rear chassis harness (see Fig 7. ( C-187)).
Wire 819 is routed from RF 4 to RK 10, which is a 31-way
interface connector. It links the rear chassis harness to the
side console harness via connector TE 10 to column
switch connector SD 2. In this way the column switch in the
cab is able to control the washer motor.

Using the wiring information for the five harnesses all wires
can be traced from source to destination. It should be
noted, however, that, unlike in the example, some wires
undergo a number change particularly when switched
through a relay.

Connectors are identified by a two letter code, e.g. FE.

Splices are also identified by a two letter code of which the

first letter is always S, e.g. SA.

On the Side Console Harness, (see Fig 9. ( C-189) to

Fig 11. ( C-191)), there are also connectors whose
codes start with S.

Splices are identified on the page by showing them in a

dotted line box.

C - 58 9803/4160-14 C - 58
 Section C - Electrics
Fault Finding
Introduction to Fault - Finding Techniques

Component Testing freely then the motor should be disassembled and the
cause identified and rectified. However, if the armature
Battery does turn freely, the motor should be given a no-load test
before disassembly.
Test the battery in accordance with the tests laid down in
Testing ( C-32). Ensure that the battery is fully The no-load test may point to specific defects which can be
charged. The wiring, switches and starter motor cannot be verified with tests after disassembly. The no-load test can
checked if the battery is defective or discharged. also identify open or shorted fields, which are difficult to
check when the motor is disassembled. The no-load test
also can be used to indicate normal operation on a
Wiring
repaired motor before installation.
Inspect the wiring for damage, renew all damaged wiring.
Inspect all connections to the starter motor, solenoid,
magnetic switch, ignition switch or any other control switch
and battery, including all ground connections. Clean and
tighten connections as required. The starting system
cannot operate properly with excessive resistance in the
circuit.

Solenoid and Switches

Inspect all switches to determine their condition. From the

vehicle wiring diagram, determine which circuits should be
energised with the starting switches closed. Use a
voltmeter to detect any open circuits.

Thermostat or Overcrank Protection

To check the thermostat for continuity, detach the wiring

harness and connect an ohmmeter to the two thermostat
terminals on the motor. The ohmmeter should read zero. If
not, the thermostat is open circuit. DO NOT check the
thermostat when it is hot, since it is supposed to be open
circuit above certain temperatures.

Motor

If the battery, wiring and switches are in satisfactory

condition, and the engine is known to be functioning
properly, remove the motor and follow the test procedures
detailed below:-

A starter motor is designed for intermittent duty only and

should never be operated for more than 30 seconds at a
time. After 30 seconds the cranking must be stopped for at
least two minutes to allow the motor to cool.

With the starter motor removed from the engine, the

armature should be checked for freedom of rotation by
prying the pinion with a screwdriver. Tight bearings, a bent
armature or a loose pole shoe screw will cause the
armature to not turn freely. If the armature does not turn

C - 59 9803/4160-14 C - 59
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Introduction to Fault - Finding Techniques

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Schematic Circuits
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Schematic Circuits
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Schematic Circuits
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C - 76 9803/4160-14 C - 76
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Schematic Circuits
426/436 from March ‘98

 




 


 

  

 







 



 




 



 



 
 


 

 



C - 77 9803/4160-14 C - 77
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Schematic Circuits
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C - 78 9803/4160-14 C - 78
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Schematic Circuits
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


















































   

C - 79 9803/4160-14 C - 79
 Section C - Electrics
Schematic Circuits
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C - 80 9803/4160-14 C - 80
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Schematic Circuits
426/436 from March ‘98



 


  
























 



 










C - 81 9803/4160-14 C - 81
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Schematic Circuits
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C - 82 9803/4160-14 C - 82
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Schematic Circuits
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








 






















 







 






C - 83 9803/4160-14 C - 83
 Section C - Electrics
Schematic Circuits
446 from March ‘98

C - 84 9803/4160-14 C - 84
 Section C - Electrics
Schematic Circuits
446 from March ‘98

 




 

  


 

 







 



 




 



 



 
 


 

 



C - 85 9803/4160-14 C - 85
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Schematic Circuits
446 from March ‘98

C - 86 9803/4160-14 C - 86
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Schematic Circuits
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


















































   

C - 87 9803/4160-14 C - 87
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Schematic Circuits
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C - 88 9803/4160-14 C - 88
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Schematic Circuits
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

 


  
























 



 










C - 89 9803/4160-14 C - 89
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Schematic Circuits
446 from March ‘98

C - 90 9803/4160-14 C - 90
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Schematic Circuits
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








 






















 







 






C - 91 9803/4160-14 C - 91
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C - 92 9803/4160-14 C - 92
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C - 93 9803/4160-14 C - 93
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C - 94 9803/4160-14 C - 94
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Schematic Circuits
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




















C - 95 9803/4160-14 C - 95
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











C - 97 9803/4160-14 C - 97
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

















C - 99 9803/4160-14 C - 99
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C - 100 9803/4160-14 C - 100

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Schematic Circuits
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









C - 101 9803/4160-14 C - 101

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C - 102 9803/4160-14 C - 102

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Schematic Circuits
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





























C - 103 9803/4160-14 C - 103

 Section C - Electrics
Schematic Circuits
426 from 532100, 436 from 533692

C - 104 9803/4160-14 C - 104

 Section C - Electrics
Schematic Circuits
426 from 532100, 436 from 533692










C - 105 9803/4160-14 C - 105

 Section C - Electrics
Schematic Circuits
426 from 532847, 436 from 534468

C - 106 9803/4160-14 C - 106

 Section C - Electrics
Schematic Circuits
426 from 532847, 436 from 534468

C - 107 9803/4160-14 C - 107

 Section C - Electrics
Schematic Circuits
426 from 532847, 436 from 534468

C - 108 9803/4160-14 C - 108

 Section C - Electrics
Schematic Circuits
426 from 532847, 436 from 534468

C - 109 9803/4160-14 C - 109

 Section C - Electrics
Schematic Circuits
426 from 532847, 436 from 534468

C - 110 9803/4160-14 C - 110

 Section C - Electrics
Schematic Circuits
Auxiliary Circuits (426 from 532847, 436 from 534468)

C - 111 9803/4160-14 C - 111

C - 112 9803/4160-14 C - 112
C6359
A6189
B6199
K6199
L A NGI S
08D8RA WR OF A088
4689
L A N GI2S88
L A RT UE N D6359
188
ES REV E R A188
L A NGI S
L ART UE N
YAL E R
S D006 B888
888
B6358
A L OOPS DR3 1 YAL E R
A368 B368 368 C611 A611 1
T B006 QB006 078 2
B L OOPS DR3 3
E468 2 YAL E R B611
B468 468 D611 178 4
MB006
RB006
568
L208 1
BT006 Y006 2
668
ES UF
611 1
CT006
Auxiliary Circuits (426 from 532847, 436 from 534468)
Schematic Circuits
Section C - Electrics
 Section C - Electrics
Schematic Circuits
Auxiliary Circuits (426 from 532847, 436 from 534468)

C - 113 9803/4160-14 C - 113

 Section C - Electrics
Schematic Circuits
Auxiliary Circuits (426 from 532847, 436 from 534468)

CT006

668

BT006

C711 568
- Bl o S
MB006
B711 + Bl o S
468
E468
711 A711 - Al o S
TB006
+ Al o S
368
E368

C - 114 9803/4160-14 C - 114

 Section C - Electrics
Schematic Circuits
Auxiliary Circuits (426 from 532847, 436 from 534468)

C - 115 9803/4160-14 C - 115

 Section C - Electrics
Schematic Circuits
Auxiliary Circuits (426 from 532847, 436 from 534468)

CT006

668

BT006

C711 568
- Bl o S
MB006
B711 + Bl o S
468
E468
711 A711 - Al o S
TB006
+ Al o S
368
E368

C - 116 9803/4160-14 C - 116

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 117 9803/4160-14 C - 117

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 118 9803/4160-14 C - 118

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 119 9803/4160-14 C - 119

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 120 9803/4160-14 C - 120

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 121 9803/4160-14 C - 121

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 122 9803/4160-14 C - 122

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 123 9803/4160-14 C - 123

 Section C - Electrics
Schematic Circuits
436 Machines - Italian Military Only

C - 124 9803/4160-14 C - 124

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 125 9803/4160-14 C - 125

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000



C - 126 9803/4160-14 C - 126

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Instrumentation

C - 127 9803/4160-14 C - 127

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000






C - 128 9803/4160-14 C - 128

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
ZF Computer and Gearbox Controller

C - 129 9803/4160-14 C - 129

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000






C - 130 9803/4160-14 C - 130

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Front Wipe, Rear Wipe, Heater/AC
and Heated Rear Screen

C - 131 9803/4160-14 C - 131

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 132 9803/4160-14 C - 132

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Front and Rear Worklights and
Beacon

C - 133 9803/4160-14 C - 133

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

 

C - 134 9803/4160-14 C - 134

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Roadlights

C - 135 9803/4160-14 C - 135

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 136 9803/4160-14 C - 136

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000



C - 137 9803/4160-14 C - 137

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Radio, Cigar Lighter, CCTV and Tow
Hitch

C - 138 9803/4160-14 C - 138

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 139 9803/4160-14 C - 139

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Suspension Seat, Reverse Fan and
ESOS, Heated Mirrors, Heated and

Emergency Steer

C - 140 9803/4160-14 C - 140

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 141 9803/4160-14 C - 141

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
12Volt Trailer Electrics and Loader
Functions

C - 142 9803/4160-14 C - 142

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000



C - 143 9803/4160-14 C - 143

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Loader Auxiliaries (Proportional)

C - 144 9803/4160-14 C - 144

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000




C - 145 9803/4160-14 C - 145

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Earthing - Cab and Cab Roof

C - 146 9803/4160-14 C - 146

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 147 9803/4160-14 C - 147

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000



C - 148 9803/4160-14 C - 148

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000
Earthing - Front and Rear Chassis

C - 149 9803/4160-14 C - 149

 Section C - Electrics
Schematic Circuits
426 from M1231500, 436 from M1305000

C - 150 9803/4160-14 C - 150

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

Primary Fuses, Ignition Switch and

Ignition Relays

C - 151 9803/4160-14 C - 151

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 152 9803/4160-14 C - 152

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Instrumentation

C - 153 9803/4160-14 C - 153

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 154 9803/4160-14 C - 154

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
ZF Computer and Gearbox Controller

C - 155 9803/4160-14 C - 155

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 156 9803/4160-14 C - 156

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Tier 3 Engine ECU

C - 157 9803/4160-14 C - 157

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 158 9803/4160-14 C - 158

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Front Wipe, Rear Wipe, Heater/AC

C - 159 9803/4160-14 C - 159

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 160 9803/4160-14 C - 160

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Front and Rear Worklights and
Beacon

C - 161 9803/4160-14 C - 161

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 162 9803/4160-14 C - 162

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Roadlights

C - 163 9803/4160-14 C - 163

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 164 9803/4160-14 C - 164

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Radio, Cigar Lighter, CCTV and Tow
Hitch

C - 165 9803/4160-14 C - 165

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 166 9803/4160-14 C - 166

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Suspension Seat, Reverse Fan and
ESOS, Heated Mirrors, Heated and

Emergency Steer

C - 167 9803/4160-14 C - 167

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 168 9803/4160-14 C - 168

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
12Volt Trailer Electrics and Loader
Functions

C - 169 9803/4160-14 C - 169

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 170 9803/4160-14 C - 170

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Loader Auxiliaries (Proportional)

C - 171 9803/4160-14 C - 171

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 172 9803/4160-14 C - 172

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000
Earthing

C - 173 9803/4160-14 C - 173

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 174 9803/4160-14 C - 174

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

C - 175 9803/4160-14 C - 175

 Section C - Electrics
Schematic Circuits
426 from M1295000, 436 from M1410000

Page left intentionally blank

C - 176 9803/4160-14 C - 176

 Section C - Electrics
Harness and Wire Number Identification
Wire and Harness Number Identification

Harness and Wire Number Identification

Wire and Harness Number Identification
TC-003

Introduction
This section details the allocation of wire numbers and the
identification of wires in the wiring harness.

Fig 1. Typical Wire and Harness Number

Fig 1. ( C-177) shows a typical connector and wires. The number stamped on the wire shown in Fig
Each wire has an individual identification number 1. ( C-177) identifies the following:
permanently marked on it, at regular intervals along it's
length.

Table 1. Wire and Harness Number Identification

Ident. No. Description
B If applicable - The colour of the flying lead that the harness wire should mate with. For instance, if wire 819
from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed
on the wire would be B-819 9/371.
819 The wire's unique identification number. The wire functions and numbers allocated to them are consistent
through out the JCB range of products.
9/371 The part number of the harness that the wire originates from. If the harness part number is 719/37100, the
number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).

C - 177 9803/4160-14 C - 177

 Section C - Electrics
Harness and Wire Number Identification
Wire and Harness Number Identification

Wire Numbers and Functions Wires 800-999

Wires 000-199 These numbers are reserved for switched supplies to

electrical loads, i.e. to lights, etc.
These numbers are reserved for ignition feeds, heater start
circuits and start circuits. These can be further categorised Wires In Splices
by:
The main input wire is allocated with a wire number and a
– Wires 000 - 099 are allocated to unfused ignition suitable description, i.e. Wire 640 earth splice to earth. The
feeds. additional wires in the splice are allocated the same wire
number and a postfix, i.e. 640A, 640B, etc.
– Wires 100 - 199 are allocated to fused ignition feeds.
Note: The letters I, O, Q and S are not used.
Note: Feeds via ignition relays are classed as ignition
feeds.
General Points
Wires 200-399
1 Wires continue to have the same number even after
passing through a connector block to another
These numbers are reserved for battery feeds, They can
harness.
be further categorised by:
2 If all the numbers in a category have been allocated,
– Wires 200 - 299 are allocated to unfused battery
then the category is re-used with an additional prefix
feeds.
'1', i.e. 1832.
– Wires 300 - 399 are allocated to fused battery feeds.

Wires 400-599

These numbers are reserved for instruments, i.e.

alternators to tachos, temperature switches to warning
lights, etc. and signal wires used in electronic systems.

Wires 600-799

These numbers are used for earth wires. When the

number is printed onto a wire 2-A it is prefixed by the Earth
symbol 2-B. This symbol is printed onto the wire, it may
however be omitted from harness drawings.

Fig 2.

Where a load is switched negative, the wire number from

the load to the switch shall be different to that of the wire
from the switch to the earth.

C - 178 9803/4160-14 C - 178

 Section C - Electrics
Harness and Wire Number Identification
Connector Location and Identification

426 from M531064, 436 from M533069

C - 179 9803/4160-14 C - 179

 Section C - Electrics
Harness and Wire Number Identification
Connector Location and Identification

C - 180 9803/4160-14 C - 180

 Section C - Electrics
Harness and Wire Number Identification
Connector Location and Identification

C - 181 9803/4160-14 C - 181

 Section C - Electrics
Harness and Wire Number Identification
Connector Location and Identification
426 from M531300, 436 from 533300,
426 from 540000

C - 182 9803/4160-14 C - 182

 Section C - Electrics
Harness and Wire Number Identification
Connector Location and Identification

C - 183 9803/4160-14 C - 183

 Section C - Electrics
Harness and Wire Number Identification
Connector Location and Identification

C - 184 9803/4160-14 C - 184

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings

Front Chassis Harness A & B - 426 from M531064, 436 from M 533069

C - 185 9803/4160-14 C - 185

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Cab Harness A & B - 426 from M531064, 436 from M 533069

C - 186 9803/4160-14 C - 186

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness A - 426 from M531064, 436 from M 533069

C - 187 9803/4160-14 C - 187

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness B - 426 from M531064, 436 from M 533069

C - 188 9803/4160-14 C - 188

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness A - 426 from M531064, 436 from M 533069

C - 189 9803/4160-14 C - 189

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness B - 426 from M531064, 436 from M 533069

C - 190 9803/4160-14 C - 190

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Cab Roof Harness A & B - 426 from M531064, 436 from M533069

C - 191 9803/4160-14 C - 191

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Front Chassis (HT) Harness - 426 from M531300, 436 from M533300, 446 form M540000

C - 192 9803/4160-14 C - 192

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Front Chassis (ZX) Harness - 426 from M531300, 436 from M533300, 446 from M540000

C - 193 9803/4160-14 C - 193

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 426 from M531300, 436 from M533300

C - 194 9803/4160-14 C - 194

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 426 from M531300, 436 from M533300

C - 195 9803/4160-14 C - 195

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 446 from M540000

C - 196 9803/4160-14 C - 196

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 446 from M540000

C - 197 9803/4160-14 C - 197

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 426 from M531516, 436 from M533478

C - 198 9803/4160-14 C - 198

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 426 from M531516, 436 from M533478

C - 199 9803/4160-14 C - 199

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - 426 from M531516, 436 from M533478

C - 200 9803/4160-14 C - 200

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - 426 from M531516, 436 from M533478

C - 201 9803/4160-14 C - 201

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - 426 from M531516, 436 from M533478

C - 202 9803/4160-14 C - 202

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Cab Harness - 426 from M531516, 436 from M533478

C - 203 9803/4160-14 C - 203

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Cab Roof Harness - 426 from M531516, 436 from M533478

C - 204 9803/4160-14 C - 204

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Controller Harness - 426 from M531516, 436 from M533478

C - 205 9803/4160-14 C - 205

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Grille Harness - 426 from M531516, 436 from M533478

C - 206 9803/4160-14 C - 206

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Under Bonnet Harness - 426 from M531516, 436 from M533478

C - 207 9803/4160-14 C - 207

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Front Chassis Harness HT - 426 from M532100, 436 from M533692

C - 208 9803/4160-14 C - 208

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Front Chassis Harness ZX - 426 from M532100, 436 from M533692

C - 209 9803/4160-14 C - 209

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Chassis Harness - 426 from M532100, 436 from M533692

C - 210 9803/4160-14 C - 210

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - 426 from M532100, 436 from M533692

C - 211 9803/4160-14 C - 211

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - 426 from M532100, 436 from M533692

C - 212 9803/4160-14 C - 212

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - 426 from M532100, 436 from M533692

C - 213 9803/4160-14 C - 213

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - Smoothshift

C - 214 9803/4160-14 C - 214

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - Smoothshift

C - 215 9803/4160-14 C - 215

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - Smoothshift

C - 216 9803/4160-14 C - 216

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Side Console Harness - Smoothshift

C - 217 9803/4160-14 C - 217

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Rear Cab Harness - 426 from M532100, 436 from M533692

C - 218 9803/4160-14 C - 218

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Cab Roof Harness - 426 from M532100, 436 from M533692

C - 219 9803/4160-14 C - 219

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Engine Harness - 426 from M532100, 436 from M533692

C - 220 9803/4160-14 C - 220

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Transmission Harness - 426 from M532100, 436 from M533692

C - 221 9803/4160-14 C - 221

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Canopy Harness - 426 from M532100, 436 from M533692

C - 222 9803/4160-14 C - 222

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Canopy Harness - 426 from M532100, 436 from M533692

C - 223 9803/4160-14 C - 223

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Canopy Harness - 426 from M532100, 436 from M533692

C - 224 9803/4160-14 C - 224

 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Canopy Fuse Box Harness - 426 from M532100, 436 from M533692

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 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Canopy Fuse Box Harness - 426 from M532100, 436 from M533692

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 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Canopy Fuse Box Harness - 426 from M532100, 436 from M533692

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Harness and Wire Number Identification
Harness Drawings
Proportional Solenoid Harness - 426 from M532100, 436 from M533692

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 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Proportional Change Over Harness - 426 from M532100, 436 from M533692

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 Section C - Electrics
Harness and Wire Number Identification
Harness Drawings
Bang - Bang Solenoid Harness - 426 from M532100, 436 from M533692

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

Drawings and Interconnection

Harnesses 426 from M1231500, 436 from

M1305000
The harness number refers to and corresponds with the
annotations in the schematic drawing.

Harness No. Issue Remarks Drawing

1 Cab Roof Harness
721/11818 3 C-246)
Main components connected to this harness: Cab harness
Front work light switch
Rear work light switch
Beacon switch
Front work lights
Front auxiliary work lights
Rear work lights
Rear auxiliary work lights
Beacon socket
Interior light
Number plate lights
Radio power and speakers
Heated mirror switch
Heated mirrors
Earth point

2 Transmission Harness
721/11826 3 C-249)
Main components connected to this harness: Output speed sensor
Turbine speed senor
Gear chain speed sensor
Engine speed
Control unit
Cab connector

3 Rear Cab Harness

721/11861 1 C-270)
Main components connected to this harness Park brake switch
Cab connector
Front washer motor
Rear washer pump
Brake light switch
Transmission disconnect switch

C - 231 9803/4160-14 C - 231

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

4 Quickhitch Locking Harness

721/11922 1 C-257)
Main components connected to this harness Front chassis connector
Quickhitch solenoid

5 Front Chassis Harness ZX

721/12149 1 C-258)
Main components connected to this harness Front lights
Horn
Lift reset
Change over
Servo isolator
Load suspension
Quickhitch locking
Shovel reset
Main harness connector

6 Front Chassis Harness HT

721/12150 1 C-261)
Main components connected to this harness Front lights
Horn
Fork reset
Lift reset
Shovel reset
Quickhitch locking
Servo isolator
Change over
Load suspension
Main harness connector

C - 232 9803/4160-14 C - 232

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

7 Engine Harness
721/11937 2 C-251)
Main components connected to this harness Cab connector
ESOS
Engine oil pressure
Air conditioning
Water temperature sender
Alternator
Starter solenoid
Starter motor
Transmission temperature sender
Air filter
Steer pressure
Brake pressure switch

8 Rear Chassis Harness

721/11938 2 C-264)
Main components connected to this harness Primary fuses
Hydraulic oil temperature switch
Fuel sender unit
Rear lights
Cab connector 1
Cab connector 2
12v Trailer feed
Fan control
Emergency steer relays
Rear grille connector
Grid heater relays
Binary pressure switch

C - 233 9803/4160-14 C - 233

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

9 Proportional Auxiliary Harness

721/11943 2 C-272)
Main components connected to this harness Proportional auxiliary options plug
ECU 4
Recovery switch
Joystick
ECU 4 indicator
Change over/Neutral relay
Side console connection
Diode pack ECU 4
Diode pack
3rd/4th spool connection

10 3rd/4th Spool Harness

721/11944 1 C-274)
Main components connected to this harness Cab connector
3rd Spool solenoid C1
4th Spool solenoid C2
4th Spool solenoid C3
3rd Spool solenoid C4

11 3rd Spool Harness

721/11945 1 C-275)
Main components connected to this harness Cab connector
3rd Spool solenoid C1
3rd Spool connector

12 Multi-Lever Harness
721/11967 1 C-276)
Main components connected to this harness Cab harness joystick plug
FNR paddle switch
Dump/Kickdown switch

13 Rear Grille Harness

721/12101 1 C-277)
Main components connected to this harness Rear chassis connector
Auxiliary lighting
Reverse alarm
Number plate light

C - 234 9803/4160-14 C - 234

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

14 Cab Harness
721/12104 1 C-278)
Main components connected to this harness Ignition switch
Column switch
Wiper motor
Chassis connector
EMS
Cab switches
Loader control lever
Transmission computer
Fuse boxes
Air conditioning
Diagnostic port
Heated screen
Road lighting

15 Pump Dump Harness

721/12164 1 C-284)
Main components connected to this harness Cab harness
Pump solenoid harness
Disable switch
Pump ECU

16 CAN Backbone Harness

727/00004 1 C-285)

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

Harnesses 426 from M1295000, 436 from

M1410000
The harness number refers to and corresponds with the
annotations in the schematic drawing.

Table 2. Cab Roof Harness

Harness No. Issue Remarks Drawing
721/11818 3 C-246)
Main components connected to this harness: Cab harness
Front work light switch
Rear work light switch
Beacon switch
Front work lights
Front auxiliary work lights
Rear work lights
Rear auxiliary work lights
Beacon socket
Interior light
Number plate lights
Radio power and speakers
Heated mirror switch
Heated mirrors
Earth point

Table 3. Transmission Harness

Harness No. Issue Remarks Drawing
721/11826 3 C-249)
Main components connected to this harness: Output speed sensor
Turbine speed senor
Gear chain speed sensor
Engine speed
Control unit
Cab connector

Table 4. Rear Cab Harness

Harness No. Issue Remarks Drawing
721/11861 1 C-270)
Main components connected to this harness Park brake switch

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

Cab connector
Front washer motor
Rear washer pump
Brake light switch
Transmission disconnect switch

Table 5. Front Chassis ZX Harness

Harness No. Issue Remarks Drawing
721/12149 1 C-258)
Main components connected to this harness Front lights
Horn
Lift reset
Change over
Servo isolator
Load suspension
Quickhitch locking
Shovel reset
Main harness connector

Table 6. Front Chassis HT Harness

Harness No. Issue Remarks Drawing
721/12150 1 C-261)
Main components connected to this harness Front lights
Horn
Fork reset
Lift reset
Shovel reset
Quickhitch locking
Servo isolator
Change over
Load suspension
Main harness connector

Table 7. Engine Harness

Harness No. Issue Remarks Drawing
332/R0851 1 C-254)
Main components connected to this harness Cab connector

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

ECM power connector

Foot throttle
Air conditioning compressor
Grid heater relay
Alternator
Starter solenoid
ECM CAN connector
Torque converter temperature sender
Air filter
Steer pressure
Brake pressure switch
ECM

Table 8. Rear Chassis Harness

Harness No. Issue Remarks Drawing
721/11938 2 C-267)
Main components connected to this harness Primary fuses
Hydraulic oil temperature switch
Fuel sender unit
Rear lights
Cab connector 1
Cab connector 2
12v Trailer feed
Fan control
Emergency steer relays
Rear grille connector
Grid heater relays
Binary pressure switch

Table 9. Proportional Auxiliary Harness

Harness No. Issue Remarks Drawing
721/11943 2 C-272)
Main components connected to this harness Proportional auxiliary options plug
ECU 4
Recovery switch
Joystick
ECU 4 indicator
Change over/Neutral relay

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

Side console connection

Diode pack ECU 4
Diode pack
3rd/4th spool connection

Table 10. Multi-Lever Harness

Harness No. Issue Remarks Drawing
721/11967 1 C-276)
Main components connected to this harness Cab harness joystick plug
FNR paddle switch
Dump/Kickdown switch

Table 11. Rear Grille Harness

Harness No. Issue Remarks Drawing
721/12101 1 C-277)
Main components connected to this harness Rear chassis connector
Auxiliary lighting
Reverse alarm
Number plate light

Table 12. Cab Harness

Harness No. Issue Remarks Drawing
Main components connected to this harness Ignition switch
Column switch
Wiper motor
Chassis connector
EMS
Cab switches
Loader control lever
Transmission computer
Fuse boxes
Air conditioning
Diagnostic port
Heated screen
Road lighting

C - 239 9803/4160-14 C - 239

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection
Table 13. Cab Roof Harness
Harness No. Issue Remarks Drawing
721/11818 3 C-246)
Main components connected to this harness: Cab harness
Front work light switch
Rear work light switch
Beacon switch
Front work lights
Front auxiliary work lights
Rear work lights
Rear auxiliary work lights
Beacon socket
Interior light
Number plate lights
Radio power and speakers
Heated mirror switch
Heated mirrors
Earth point

2 Transmission Harness
721/11826 3 C-249)
Main components connected to this harness: Output speed sensor
Turbine speed senor
Gear chain speed sensor
Engine speed
Control unit
Cab connector

3 Rear Cab Harness

721/11861 1 C-270)
Main components connected to this harness Park brake switch
Cab connector
Front washer motor
Rear washer pump
Brake light switch
Transmission disconnect switch

4 Quickhitch Locking Harness

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

721/11922 1 C-257)
Main components connected to this harness Front chassis connector
Quickhitch solenoid

5 Front Chassis Harness ZX

721/12149 1 C-258)
Main components connected to this harness Front lights
Horn
Lift reset
Change over
Servo isolator
Load suspension
Quickhitch locking
Shovel reset
Main harness connector

6 Front Chassis Harness HT

721/12150 1 C-261)
Main components connected to this harness Front lights
Horn
Fork reset
Lift reset
Shovel reset
Quickhitch locking
Servo isolator
Change over
Load suspension
Main harness connector

7 Engine Harness
332/R0851 1 C-251)
Main components connected to this harness Cab connector
ECM power connector
Foot throttle
Air conditioning compressor
Grid heater relay
Alternator
Starter solenoid
ECM CAN connector

C - 241 9803/4160-14 C - 241

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

Torque converter temperature sender

Air filter
Steer pressure
Brake pressure switch
ECM

8 Rear Chassis Harness

721/11938 2 C-264)
Main components connected to this harness Primary fuses
Hydraulic oil temperature switch
Fuel sender unit
Rear lights
Cab connector 1
Cab connector 2
12v Trailer feed
Fan control
Emergency steer relays
Rear grille connector
Grid heater relays
Binary pressure switch

9 Proportional Auxiliary Harness

721/11943 2 C-272)
Main components connected to this harness Proportional auxiliary options plug
ECU 4
Recovery switch
Joystick
ECU 4 indicator
Change over/Neutral relay
Side console connection
Diode pack ECU 4
Diode pack
3rd/4th spool connection

10 3rd/4th Spool Harness

721/11944 1 C-274)
Main components connected to this harness Cab connector
3rd Spool solenoid C1
4th Spool solenoid C2

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

4th Spool solenoid C3

3rd Spool solenoid C4

11 3rd Spool Harness

721/11945 1 C-275)
Main components connected to this harness Cab connector
3rd Spool solenoid C1
3rd Spool connector

12 Multi-Lever Harness
721/11967 1 C-276)
Main components connected to this harness Cab harness joystick plug
FNR paddle switch
Dump/Kickdown switch

13 Rear Grille Harness

721/12101 1 C-277)
Main components connected to this harness Rear chassis connector
Auxiliary lighting
Reverse alarm
Number plate light

14 Cab Harness
721/12104 1 C-278)
Main components connected to this harness Ignition switch
Column switch
Wiper motor
Chassis connector
EMS
Cab switches
Loader control lever
Transmission computer

C - 243 9803/4160-14 C - 243

 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

Fuse boxes
Air conditioning
Diagnostic port
Heated screen
Road lighting

15 Pump Dump Harness

721/12164 1 C-284)
Main components connected to this harness Cab harness
Pump solenoid harness
Disable switch
Pump ECU

16 CAN Backbone Harness

727/00004 1 C-285)

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Harness and Wire Number Identification
Drawings and Interconnection
Drawings

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 Section C - Electrics
Harness and Wire Number Identification
Drawings and Interconnection

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Drawings and Interconnection

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Drawings and Interconnection

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Drawings and Interconnection

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Harness and Wire Number Identification
Drawings and Interconnection

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Harness and Wire Number Identification
Drawings and Interconnection

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Harness and Wire Number Identification
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Drawings and Interconnection

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Harness and Wire Number Identification
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Harness and Wire Number Identification
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 Section C - Electrics

Electronic Monitoring System

System Identification

General The current EMS system (HC11) can be identified by the

following part numbers:
January 2006 will see the introduction of a new advanced
type of EMS to the Large Wheeled Loading Shovel – EMS GA: 728/80056
machine range. This will coincide with the introduction of – EMS Hardware: 728/27700
the new style cab, and primarily facilitates the introduction – EMS Software: 728/90230.hex
of the Tier 3 Common-Rail engines.
Important: This EMS MUST be Set-up using the current
Unfortunately, it is not easy to differentiate between the TERM 2 Software Tools. HC11 EMS ( C-288).
two EMS systems as visually they are identical. However,
the EMS units will have unique Hardware and Software
JCB part numbers. These part numbers are the only way
to guarantee correct identification.

Although the part numbers are clearly marked on the rear

of the display units, viewing them would require the unit’s
removal. However, the units are programmed to display
the software part number on the top of the display screen
at start-up.

Important: It is vital that you identify the correct software

package before attempting to connect the diagnostic tools.
Serious damage may result from an incorrect connection.

The software identification part number will be displayed

for approximately 1.5 seconds each time the system is
powered up. If you fail to fully identify the part number at
the first attempt, turn off the ignition, wait 2 - 3 seconds and Fig 81.
then turn the ignition on again. Repeat this procedure as
many times as necessary until the software has been
correctly identified.

The new system (C164) will be identified by the following

part numbers:

– EMS GA: 728/80077

– EMS Hardware: 728/30400
– EMS Software: 728/90269.vsf.

Important: This EMS MUST be Set-up using

Servicemaster 2. C164 EMS ( C-308).

Note: Only the digits of the software part numbers are

displayed, ie, 728/990269. The.vsf for the C164 nor the
.hex for the HC11 are not displayed on screen.

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS

HC11 EMS

Description editor. The third function is to view machine fault logs

saved in the EMS. This part of JCBTerm is known as the
Important: Before attempting any diagnostic work on the Log Viewer. The last function is to view or change the
system, ensure that you have correctly identified the current serial number.
software package. Please refer to System
Identification ( C-287). The Main Screen

Introduction When the program is started, the main screen appears,

Fig 82. ( C-288). The buttons on the left allow you to
JCBTerm is a Windows based program which interfaces choose the function you would like to perform. The Com
with the Electronic Monitoring System (EMS). The Port selection on the right allows you to choose which
JCBTerm software serves four functions. The first is to communication port the EMS is connected to. All of the
download a new version of software into the EMS. This selections have short cut keys indicated by the underlined
section of the program is referred to as the flash letter or number. Short-cut keys are accessed by holding
downloader. The second is to retrieve and modify different down the Alt key and pressing the underlined character.
setup values in the EMS. This is known as the settings









 
 




 





Fig 82. The Main Screen

Note: There are also menus available at the top of the

screen. The “File” menu provides an alternate means of
performing the actions controlled by the buttons. The
“About” menu gives information about JCBTerm. Fig
82. ( C-288)

Flash Downloader

The flash downloader allows you to download a new

version of firmware into flash memory on the EMS. A
screen shot of the flash downloader is shown. Fig
83. ( C-289).

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS





 


 












Fig 83. Flash Downloader Screen

Preparing to Transfer a Program if the transfer was successful. This check is usually quite
fast. Third, the status box notifies you that the flash
The “Main Program File” box shows which file will be memory is being erased. This normally only takes 3-4
downloaded into the EMS. The most recent file is shown in seconds, but may take as long as 2 minutes in extremely
the file selection box. Pressing the drop down button on the rare circumstances. The status bar should increment to let
box reveals the four most recent files. If a different file is you know that it is functioning properly. Lastly, the code is
desired, click the “More Files” button and you will be able transferred to the EMS. The time it takes to do this will vary
to select from a file selection box. with the size of the software, but normally takes 30s - 60s.

The “Flash Loader Program” box shows which file will be At any time during the transfer you may press “Cancel” to
used to program the main program file into flash memory. abort the transfer. If you do this before the flash memory
This program is distributed with JCBTerm and can be starts to erase, the contents of the flash memory will be
found in the directory which the program was installed to. retained. If this is done at any other time during the
It should be the only file with a.hex extension. Under transfer, the EMS will most likely be unusable until a valid
normal circumstances, the same flash loader program file file transfer has been completed.
should always be used. Like the “Main Program File” box,
the four most recent selections are available. Once the transfer is complete, a box will notify you that it
has been completed. Click “OK” on this box to clear the
Transferring the Program message. If there is an error at any time during the
transfer, a message box will display a description of the
The “Send” button will begin transferring the selected error as well as a flash downloader error code number. If
program into the flash memory in the EMS. Note that the you require technical assistance, please note the error
EMS must be placed into bootstrap mode before the message and the error code number.
“Send” button is clicked. Once the button has been
pressed, the program will take a few seconds to prepare It is also helpful if you are able to determine a sequence of
the files for sending. Once it is ready to send the file, a events which will reproduce the error, and at what point
status bar will come up and keep you updated on four during the download the error occurred (i.e. sending
different events as they occur. flashloader, verifying flashloader, erasing flash, or sending
main program).
First, the flash loader program is sent to the EMS. When
this is complete, the status bar is reset and begins to check

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS
Exiting the Flash Downloader Settings Editor

To exit the flash downloader, click the “Exit” button. The settings editor allows you to change operating
Pressing Alt-X, Ctrl-X, or escape which also exits the flash parameters of the EMS. A screen shot of the settings editor
downloader. is shown Fig 84. ( C-290). The settings editor shows
the current settings, allows new values to be entered, and
allows them to be programmed into the EMS.




  

  
    

  

  

  

 

 

 

 

  

  

 

  

 

 
 
 
 

  

A278030-V1

Fig 84. Settings Editor Screen

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS
Viewing Current Settings restore the cell to its previous contents. Pressing Enter,
down arrow, or up arrow will place the entered value in the
Whenever the settings editor is started up, there must be cell. Notice that the values are limited to a range. This is to
an EMS connected to the PC. All information about which prevent ridiculous values from being entered.
set points may be changed and the legal values for those
settings are all stored on the EMS. The settings editor must The settings editor has the ability to display units as either
be able to download information from an EMS before the metric or imperial, even though the EMS expects each
information can be displayed. setting to be in a particular unit of measure. This is done by
recognising which unit of measure the EMS expects, and
If you would like to refresh the information shown on the converting as necessary to either metric or imperial.
screen because a different unit was connected, click on
the “Update Display” button. The current information is To view settings in the preferred units of measure, click on
retrieved and displayed on the screen. the desired option in the Units Standard selection box.
Since different units are supported and the resolution of
If you would like information about the set points, choosing the settings is determined by the units that the EMS is
“About Settings” from the About menu will give you using, you may observe what at first may appear to be
information such as the version number of the set points, strange behaviour. However, it is quite logical, and is not a
the project number, and the serial number of the unit the bug. Suppose that the EMS sends and receives data for
settings were retrieved from. the coolant temperature alarm in °C. If the imperial
standard is preferred, then the program will convert to °F.
In the Settings Editor Screen Fig 84. ( C-290). The If the current setting was 105°C, the EMS would display
data is organised into four columns. The first column, 221°F. Suppose you wish to change this value to 240°F.
“Setting Description” is simply a description of the setting. Because the EMS expects values in °C, this value is
The second column, “Current Setting”, shows the value of converted to 115.55556°C. However, the value of this
the setting which is in the EMS. The third column, “Desired setting is limited to a resolution of 1°C, so it is rounded off
Setting”, allows you to enter in a different value. The last to 116°C. Notice that 116°C converts to 240.8°F, which
column, “Unit” shows the units the values are shown in. rounds off to 241°F. Therefore, if 240°F is entered, 241°F
will actually be shown. Other settings, such as the Anti-
Changing the Settings stall rpm may be limited to other resolutions. Entering a
value of 554 rpm for example will display a value of 550
There are two types of settings. The first type has a defined rpm because the Anti-stall rpm value is limited to a
set of values which may be selected. Such settings are resolution of 10 rpm.
identified with an icon in the desired settings column. An
example is the model type. It can be either FRM 412, FRM Writing Settings to the EMS
414, JCB 446, LDR 411, LDR 426, LDR 436, or LDR 456.
To change these settings, either click on the box or press Settings are written to the EMS by clicking the “Update
either Enter, the space-age, or the left or right arrow keys. EMS” button. When this is done, a sequence of events
occurs. First, settings information is retrieved from the
The second type of setting may be any value within a EMS. This is done to make sure that the same unit with the
certain range, but limited to a certain resolution. The same set of settings is still connected to the PC. If an EMS
resolution of a setting is the smallest change that can be with a different version of settings was connected in
recognised for that setting. The resolution of each setting between, blindly writing the settings could have a
may be different. For example, the resolution of most catastrophic effect on the operation of the EMS.
temperature settings is 1°C. This means that these
settings are rounded to the nearest degree. Second, the PC checks to see which settings are different
and transmits any values which need to be changed.
There are different ways to edit the value of these set
points. Double-clicking on a box will allow you to edit the Lastly, the settings information is read back from the EMS.
value currently shown in the desired heading column. Although it is known what the values should be, this allows
Clicking once on a desired value and the starting to type verification that all values have been properly written. If the
will overwrite whatever was previously shown in the EMS reports an error while writing a value to the EMS, it
desired setting column. If you are editing a desired setting will be reported to the user. Any values which were not
and press Escape, it will cancel what you have typed and

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS
correctly written will not have a blank “Desired Setting” in the file are shown in bold until a value is entered for
column. them.

Saving Settings to Disk Closing a Settings File

If there is a setup that is frequently used, it is possible to If you have finished using a settings file, you may close it
save it to disk. The setup may be recalled in the future so the PC knows that you are not editing the currently
without having to re-enter all of the settings manually. This loaded file. Also, the filename will no longer appear at the
can be useful to quickly configure EMSs’ for different bottom of the window.
vehicles; a file can be created for each model and recalled
when necessary. If the file is left open, and changes are made, the PC will
think that the file should be saved and prompt if this should
Once all settings are properly entered and the setup is be done. Although it is possible to choose not to do this, it
ready to be saved, choose “Save” from the “File” menu at is always a good idea to close the file when you have
the top of the window. A box will come up prompting you finished with it to prevent accidentally over-writing the file.
for a filename and path. Once this is entered, the current
settings will be saved under that filename. Any time you Exiting the Settings Editor
wish to recall these settings, load this file.
Clicking on the “Exit” button, or pressing Ctrl-X or Alt-X on
Loading Settings from Disk the keyboard will return to the main start-up screen. Before
exiting however, the program checks to see if a file has
If a setup has been saved as described in the previous been modified and that all edited set points have been sent
section, it can be recalled in order to configure another unit to the EMS. If they haven’t, warning messages are
with the same settings. Note that loading settings from disk displayed before exiting, with the option to cancel.
is equivalent to entering the settings from the keyboard.
The EMS is not automatically programmed, and it still Log Viewer
requires that the settings are written to the EMS, as
described in Writing Settings to the EMS ( C-291). Each EMS will record information on system faults since it
has been last serviced. This is partially dependent on how
To load settings from disk, choose “Open” from the “File” the EMS was setup with the settings editor, described
menu at the top of the window. A box will appear to prompt earlier in Writing Settings to the EMS ( C-291).
you for a filename for the settings file. Once the desired file Since the amount of information which can be stored may
has been selected, click the “OK” button or press enter and not be enough to store all events throughout the EMS’s life,
the settings will be shown as if they had just been entered. these logs should be downloaded and reset at regular
Note that they will only be entered if the settings exist; if no service intervals. Each time the logs are reset, dealer and
settings are loaded, nothing will change on the screen. engineer codes are stored in the service log.
First load the settings from the EMS you want to apply the
changes to, then load the file. There are two sources of log information. One source is
from a file saved to disk. The other source is directly from
There is also a short-cut method to open files which have the EMS itself. There are two ways of retrieving logs from
been recently used. If the file you want to load is one of the the EMS. The first is to just view logs. This allows the user
four most recently loaded files, it will appear at the bottom to download and view the logs with the option of saving to
of the “File” menu. Selecting the correct file from the a file. The other way of retrieving logs is to retrieve the logs
bottom of the “File” menu is equivalent to choosing the file and reset the log information. This requires the user to
from the file selection box. enter a dealer code, an engineer code, and a filename.
This information is then stored in the service log.
If the settings appear to be different from the settings
currently loaded, a warning will be issued that the settings
may not be for the currently connected EMS. The option is
presented to load the settings anyway or to abort the load
procedure. If the settings are loaded anyway, settings with
matching descriptions are entered. Settings which are not

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS


 
 
    
 
   
    
      
    
      

 
      


   
   
    



    



   

    
   







A278040-V1

Fig 85. Log Viewer Screen

A screen shot of the Log Viewer is shown. Fig If it is yellow, it means the PC is busy, but the user may
85. ( C-293). begin interacting with the interface.

Note: The upper left corner contains information about the If the status bar is green, the PC has finished processing
logs and the EMS the logs were downloaded from. There and all parts of the interface are available to the user.
are also three buttons to retrieve a different or new set of
logs. Downloading Logs from the EMS

The upper right corner, labelled “Since last service:” Viewing and Resetting the Logs
contains various maximum and minimum values since the
logs were last reset. Log information is stored in the EMS’s memory. At regular
intervals, this information should be downloaded, saved to
The buttons on the right side of the screen allow more disk, and reset on the EMS. This is all done automatically
information to be shown on different events, or view with the action of click on the View and Reset button in the
filtering to be changed. box at the upper left hand corner of the window.

There is a status bar at the bottom of the screen which When the “View and Reset” button is clicked, the user is
updates the user on events as they happen. prompted for a dealer code, an engineer code, and a
filename. The dealer and engineer code is stored in the
If the status bar is red, the PC is busy and nothing should service log. The filename is the file that the log information
be done by the user. will be stored to. By saving all information to a file, the risk
of losing data is reduced. If the file entered in the file

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS
selection box is the name of a currently existing file, Last Minutes Running Data Information
confirmation is required to make sure that it is acceptable
to overwrite the current file. Some events also have some extra data associated with
them. This extra data is the last one minutes worth of
Once this information has been provided, the transfer important engine information prior to the events
begins. During the transfer, the status bar is red, and the occurrence. Events which have this extra information have
interface is disabled. Preliminary information should a running data icon in the “More” column of the grid. The
appear in the top boxes as soon as it is available. running data icon looks like this:.
Depending on how much log data there is, a transfer can
take anywhere from a few seconds to over a minute.

After the transfer is complete, messages will appear if There is more than one way to bring this data onto the
there were any problems with the download, or if there are screen, but the simplest method is to double click the
any memory problems on the EMS. If there were no running data icon. Regardless of how the information was
problems, the log information will be automatically reset. called, a window such as the one shown will appear Fig
The status bar will also indicate this. 86. ( C-295).

If the PC detects errors when downloading the logs, it will

ask whether or not the logs should be reset. Before
resetting the logs, try downloading the logs a few more
times and see if the problems persist. If the errors
continue, the logs should be reset.

Viewing the Logs only

If you do not wish to reset the logs but would like to see log
information, click the “View From EMS” button in the box at
the upper left hand corner of the window. You will be given
the option of saving to a file. Once you have supplied a
filename or if you decided not to save to a file, the transfer
begins.

The transfer is the same as if you had chosen to view the

logs and reset, except that the logs are not reset at the end
of the transfer.

Viewing Logs from a File

Once log information has been downloaded and saved to

a file, it may be viewed again at any time. To do this, click
the “View From Disk” button in the box at the upper left
hand corner of the window. This brings up a file selection
box. Once the desired file has been selected, click “OK” or
press enter. This loads the file and displays the information
on the screen.

Recently viewed files are available at the bottom of the

“File menu”. Selecting one of these files is equivalent to
selecting the file from the file selection box. This is a short-
cut provided to ease the selection of frequently viewed
files.

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS


       
     
     
  
     
  
     
  
     
  
     
  
     
  





Fig 86. Last One Minute of Running Data Screen

Note: The time starts at 0s and decreases down to -55s. event, just double-click anywhere on the event, except the
The 0s sample is the most recent data available at the time running data icon, if there is one, if there s one. When this
the event occurred. The -55s sample is the data from 55 is done, a message box will appear, like the one shown
seconds before the event occurred. Fig 87. ( C-295). The first line, labelled Event Name,
simply gives a description of the event. The second line,
Event Occurrence Information Event Occurrence, shows the relative occurrence of this
event to other events of the same type. The last line gives
Occurrence information can be viewed about any event, or the relative occurrence of this event to all other events. To
about all events in general. To get information on a specific clear this message box, click on the “OK” button.













A278060-V1

Fig 87. Event Occurrence Information Message Box

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Electronic Monitoring System
HC11 EMS
Note: There is also a description of how many events are One thing which should be clarified is that the number of
missing. If the EMS's memory should happen to fill up occurrences column, which shows how many events may
before it can be serviced, the EMS has no choice but to be seen on the screen; it does not include missing events
erase some of the other data in order to keep logging more in its total.
recent data. If this happens, the number of erased events
will be shown as missing. Detailed information about these Service Logs
events cannot be recovered.
The service logs can be viewed by clicking on the “Service
To view occurrence information about all events in Logs” tab underneath the grid, Fig 85. ( C-293). This
general, click the “View Info” button at the right side of the displays when the machine was serviced, and by whom.
screen (see Fig 85. ( C-293)). This will bring up a To return to the fault logs, click the “Fault Logs” tab
screen which shows the number of occurrences of each underneath the grid.
type of event, as well as how many of each type of event
are missing. A partial view of this screen is shown in Fig
88. ( C-296).


  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  



A278070-V1

Fig 88. Occurrence Information For All Events Screen

Printing Logs Although JCBTerm tries to select a suitably sized font, it is

difficult to be sure the default font will always look correct.
To print the logs on the default printer, select the “File” If the font JCBTerm chooses causes columns to overlap,
menu and then “Print”. Information at the top of the screen or if the table looks too crowded, it is possible to select a
will be printed first, followed by the service logs. The fault different font.
logs are printed after the service logs. The last minute's
running data information is printed in an indented table To choose a font, select the “File” menu and then “Set
directly under the associated event. Printer Font”. JCBTerm will determine which fonts are
available on the default printer, and presents them to you

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Electronic Monitoring System
HC11 EMS
in a list box. You can select a different font from this list and categories. For example, the “Transmission Oil System”
try printing again. In general, fixed pitch fonts should be 12 category includes the “Transmission Oil Level”,
or more characters per inch (cpi). When choosing fixed “Transmission Oil Pressure Low”, and the “Transmission
pitch fonts, select one which is 12-17 cpi. Oil Temperature High” events.

Filtering the View Once the screen appears, the desired categories can be
selected. Note that there are “Select All” and “Select None”
The logs can contain many different types of events and it buttons to speed up the selection process. The “Select All”
can be difficult to focus on certain events. To aid in this button automatically selects all categories and the “Select
respect, a view filter has been added so that only events of None” button automatically dissects all categories. After
a certain type may be shown, if desired. To choose which the appropriate selections have been made, click “OK”. If
events to view, click on the “Select” button under the “Filter the filter wasn't applied, a prompt will appear asking if the
Options” heading (see Fig 85. ( C-293)). filter should be applied according to the selections just
made.
Not all event types are listed individually on the selection
screen. Instead, the events have been broken down into




 

  

 

 

 

 

 

A278080-V1

Fig 89. Log Filter Selection Screen

Once the filter selections have been made, the filter may Exiting the Log Viewer
be turned on and off as desired. The button which toggles
the filter is just above the “Select” button which was used To return to the main screen, click the “Exit” button. Also,
to change the filter settings (see Fig 85. ( C-293)). If you may press Alt-X or Ctrl-X from the keyboard.
this button is labelled “View All”, it indicates that the filter is
currently applied. Clicking on the bottom will remove the Serial Number Editor
filter and allow all events to be shown. If the button is
labelled “Filter View”, it means that the filter is not currently Each EMS has a serial number stored in its memory. The
applied. Clicking on the button will apply the filter and show serial number editor provides a way of writing the serial
only the selected types of events. number to the EMS. Normally, this may only be done once.
However, if the file “SRNMLOCK.EXE” was included on

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Electronic Monitoring System
HC11 EMS
the install disk, special permission is granted to allow the connected to the port. To start the serial number editor,
serial number to be written more than once. click the “View/Change S/N” button from the main screen
(see Fig 82. ( C-288)).
Before starting the serial number editor, make sure the
correct com port is selected, and that the EMS is




 









A278090-V1

Fig 90. Serial Number Editor Screen

When the serial number editor is invoked, it checks for the Writing the Serial Number
current serial number, and checks if the serial number is
locked. This information is shown on the screen. The text To write a new serial number to the EMS, type the desired
box allows a new serial number to be entered. The buttons serial number in the text box, and click on the “Write S/N”
at the right side of the screen allow certain actions to be button next to the text box. If this button is not active, it is
performed. because the serial number is locked or because the serial
number editor was unable to connect to the EMS to get
Unlocking the Serial Number current information. To unlock the serial number,
Unlocking the Serial Number ( C-298). To try to
Once the serial number has been written, it will be locked reconnect to the EMS to get current information,
so that it may not be changed. In order to unlock the serial Refreshing Serial Number Information ( C-298).
number, the “SRNMLOCK.EXE” file must be in the install
directory of the program. For example, if JCBTerm was If there are no problems, the serial number will be written
installed to C:\JCB, then “SRNMLOCK.EXE” must be and locked. The new serial number will appear beside the
copied from the installation disk to C:\JCB. If “Current S/N:” label. The S/N lock status should be locked.
“SRNMLOCK.EXE” is not on the installation disk and it is If this is not the case, the serial number was not properly
not in the JCBTerm install directory, permission is not written.
granted to unlock the serial number.
Refreshing Serial Number Information
If the serial number is locked, and “SRNMLOCK.EXE” is in
the install directory, the “Unlock S/N” button will have bold If the information regarding current serial number and lock
lettering, as shown Fig 90. ( C-298). This indicates status is not current, it can be refreshed at any time by
that this action may be performed. Clicking on this button pressing the “Refresh Data” button. This will get the
will unlock the serial number. The information on the current serial number and lock status from the EMS
screen will be refreshed and the serial number should no connected to the PC.
longer be locked.
This should be done any time a different EMS is connected
to the PC because the serial number editor is unable to

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS
detect when a change has occurred. This may also be
done if the serial number or lock status is shown as
“Unavailable”. This would most likely be caused by the
wrong com port being selected, an EMS not being
connected to the PC, or if the EMS was not powered up.

Exiting the Serial Number Editor

To return to the main screen, click the “Exit” button or press

Esq. from the keyboard.

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Electronic Monitoring System
HC11 EMS

Connecting up the Laptop 10 Access program.

Before visiting machine Windows 3.31 - From Program Manager, double click
on “JCBTerm” program group, double click on
1 Ensure latest version of JCBTerm is on laptop, and “JCBTerm” Icon.
available on floppy disc.
or
Note: Both 3.31 and 95 versions must be carried.
Windows 95 - Select “Start” button, point at
2 Ensure laptop battery is fully charged. “Programs”, point at”`JCBTerm VXX”, “Select
JCBTerm”.
3 Check connection cable (892/00930) is in good
condition. 11 Check that Serial Number on screen is the same as
that on machine. If they do not agree, contact
On machine Distributor immediately.

4 Remove armrest and rubber mat. 12 Check that upgrade of EMS matches that of laptop, if
not make note to upgrade before leaving machine.
5 From diagnostic plug 91-A, in the fuse box., remove
blanking plug 91-B

Fig 91.

6 Fit the 9-way end of the connecting cable into the

Com 1 port of the laptop and secure.

Note: Do not start engine.

7 Switch on ignition and allow EMS to complete start-up

routine.

8 Fit 6-way end of connecting cable to diagnostic plug.

9 Switch on laptop.

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Electronic Monitoring System
HC11 EMS

Before Starting Service


 

1 Connect laptop to EMS.  

    
    

    
2 Access “JCBTerm program.” 



 


 


      

 
3 Select “Get Log Data” button.        


   
   
    

   


 


   



    
    


 

 



A278040-V2

 Fig 93.

 On completion of Service


1 Connect laptop to EMS.

2 Access “JCBTerm program.”

A278010-V2

Fig 92. 3 Select “Get Log Data” button.

4 Select “View and Reset” (you will be prompted to

save “Logs to Disc'' 

5 Do you want to enter log file “YES/NO” enter “No”. 


6 View the “Fault Log” as required.

 
 
7 Exit the viewer.



 





Fig 94.

4 Select “View and Reset” (you will be prompted to

save “Logs to Disc''

5 View the “Fault Log” as required.

6 Select “View From EMS” (You will be prompted to

“Save Logs to Disc” Type a file name such as M/CS/

C - 301 9803/4160-14 C - 301

 Section C - Electrics
Electronic Monitoring System
HC11 EMS
No. followed by 01, 02 etc and select “OK” i.e. 11 Type in the “Next Service Hours” (400 after a 100hr.
53900101. service. 500 after all others).

7 You will be prompted to enter: 12 Select “Update EMS” (You will be prompted to save
the changes select “YES”).
Your “Dealer Code”, enter code and select “OK”.

Your “Engineer Code”, enter code and select “OK'. 



8 Exit the “Events Log” screen.  

   
  
 

  

 
  

    

    
       

    
        
    
      
  

 
 
          

      
   
      
 
        



     

    
      

  
  
 


  

A278040-V2

Fig 95. 

Fig 97.
9 Select the “View/Change Settings” button from the
main screen. 13 Exit the 'Settings Editor”.

14 Exit the program.




 
 


  
 
  
 

 




  







Fig 98.

Fig 96. 15 Switch off laptop.

10 Click on the white screen in the “Service Due Hours”

row.

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HC11 EMS
16 Disconnect, both ends, and remove connecting
cable.

17 Fit blanking plug to flying lead.

18 Fit arm rest and rubber mat.

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS - Software

HC11 EMS - Software

Important: Before attempting any diagnostic work on the 18 Go to Transfer new program. In program file, using
system, ensure that you have correctly identified the Browse, insert file ZFV2_07.HEX.
software package. Please refer to System
Identification ( C-287). 19 In flash loader file, using Browse, insert file
FDL436_5.HEX.
Installation
20 Your program is now ready to use.
To install the software onto the laptop computer:
Installation from Techweb
1 Insert JCB Disk 3. JCB_CD3
To install the software onto the laptop computer:
2 Using windows explorer, locate and open CD Drive.
1 Using windows explorer, locate and open Techweb.
3 Open file Wheeled Loader Software.
2 Open file Wheeled Loader Software.
4 Open file D1.
3 Open file D1.
5 Double click on set up, the 45KB application file.
4 Double click on set up, the 45KB application file.
6 Follow instructions until you get to insert Disk 2.
5 Follow instructions until you get to insert Disk 2.
7 Using browse command locate D2 on CD drive and
OK twice. 6 Using browse command locate D2 on Techweb and
OK twice.
8 Follow instructions to the end.
7 Follow instructions to the end.
Note: if you get an error message, setup 3, just press OK
and ignore. Transfer New Program
9 Close and re open windows explorer. You should now
find under (C:) JCB2. A Connect interrogation lead to communication port
of machine. See Connection of Interrogation
10 Open CD drive. Lead ( C-307).
B Switch ignition ON.
11 Open file Wheeled Loader Software.
This gives just a background illumination of the EMS (no
12 Locate file ZFV2_07.HEX click, hold, drag and drop in display).
file JCB2 in C: drive.
1 Open JCB Term 2.
13 Close down Explorer.
2 From the main welcome page, click on Transfer
14 Go to Start menu. New Program ( C-304).

15 Go to programs. 3 In the top box (Program File) insert the latest file. The
current file would read C:\JCB2\ZFV2_07.HEX. This
16 Go to JCB Term 2 and open. is found by clicking on browse and looking on C: drive
then locating JCB2, highlight the necessary file and
17 Go to set up and set Com Port to com1. click OK.

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS - Software
4 In the second box (Flash File) insert the latest file, the Note: your only have one opportunity so you must get the
current file would read C:\JCB2\FDL_5.HEX, this is numbers correct.
located using the same method as above.
Log Data
5 In the third box (Alternative Language) Using the
downward facing arrow, select the required language
for the EMS display. A Switch ignition ON.
B Connect interrogation lead to communication port
6 Click on send. You will be asked to turn the EMS off of machine. See Fig 100. ( C-307).
and on, Follow the instructions.
In this configuration you will see the EMS display.
7 The bottom box will now display the progress as a %
complete. 1 Open JCB Term 2.

8 You will now be asked to recycle the EMS. 2 From the main welcome page click on Log
Data ( C-305).
a Switch ignition OFF.
3 Click on the Icon Loading shovel to computer in the
b Disconnect the interrogation lead from the bottom LH corner of the screen. This will copy the
communication port. information from the EMS to the computer.

c Switch ignition ON. 4 Once you have completed step 3, click on the icon
Reset Logs, to clear the EMS memory. You will now
d Reconnect the interrogation lead. be asked for:

Press OK. The languages will be loaded. a Your dealer code.

Any new versions of the software to will be issued via the b Your individual identification.
JCB CD-ROM, normally on CD 3. The method for copying
the new software into your JCB Term2 is to open windows c Any service information that you require to log.
explorer with the CD installed open Wheeled Loader
Software, click, hold, drag and drop the new software into The fault log will then be logged into to EMS date
JCB Term2. base against the machine serial number and the
date.
Serial Number
5 The Log Data screen has various pages of
information, Fault log. Extended log, Max - min's,
A Switch ignition ON.
Occurrences, Erased faults, Service logs and Filter
B Connect interrogation lead to communication port select.
of machine. See Connection of Interrogation
Lead ( C-307). a Fault log: - The master list of all faults since the
last service.
In this configuration you will see the EMS display.
b Extended log: - Where a fault on the master list
1 Open JCB Term 2. has further information, (identified by a digger icon
in the more column) you can highlight the fault
2 From the main welcome page click on Serial and look at extended log. Can also be used with
Number ( C-305). the More icon at the bottom of the screen.

3 Type in the serial number and then click on the icon c Max - Min: - Will show various temperatures etc
Computer to Loader. encountered since the last service.

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS - Software
d Occurrences: - Will show the number of 4 The settings from the machine will be displayed as
occurrences of any specific fault highlighted on follows:-
the Fault log screen.
Min Alt Voltage, 20.0 volt
e Erased Faults: - Due to the fact than the EMS has
a limited memory if the memory becomes full, the Min Battery Voltage, 23.0 volt
EMS will drop the faults in age order and log the
fault in erased faults. Low Fuel alarm point, 10 %

f Service logs: - Every time a service is carried out Hyd Oil Temp high alarm point, 120°C
and the Reset Log command is carried out, it will
be logged on this page and cannot be erased. Coolant Temp high alarm point, 103°C
This is a Permanent Service history of the
machine. Service Interval, 0

g Filter select: - If you want to look at specific area Model Type, As Per Machine
faults (i.e. Transmission) you can turn on just this
area by putting a cross against your desired area. Rolling Radius, As Per Tyre Spec

6 To look at historic fault logs, click on the small down Powered H/Brake, Yes/No 456 Only
arrow against serial number and scroll down until you
find the serial number your require. If there is more Rear Window heater on time, 20 Min
than one entry against that serial number, specify by
date. Engine turn off time, 0 Min

Fault Limit Settings 5 Any changes are made by clicking in the value box in
line with the setting to be changed, make the change
then clicking on the icon that shows a computer with
A Switch ignition ON. an arrow pointing to a Loading Shovel.
B Connect interrogation lead to communication port
of machine. See Connection of Interrogation 6 The only figures that you should normally change
Lead ( C-307). would be:

In this configuration you will see the EMS display. Low Fuel alarm point which can be set to any 5%.

1 Open JCB Term 2. Service interval should be set when a service has
been done, to give the interval to the next service.
2 From the main welcome page click on Fault Limit
Settings ( C-306). Rear window heater on time is factory set to 20 min,
it can be varied to suit location.
3 Click on the icon of a loading shovel with an arrow
pointing to a computer. Engine turn off time can be set to any length of time,
when no gear selections have been made for the set
time then the engine will stop.

Note: The machine will still have ignition ON, so any

ignition fed electrical item will remain live (lights, heater
etc) which could drain the battery if left for a long time.

7 Rolling Radius - The rolling radius for tyres fitted to

JCB wheeled loaders are as the attached chart.

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 Section C - Electrics
Electronic Monitoring System
HC11 EMS - Software

Tyre Size Rolling Radius Machine

15.5 R 25 XHA 604 411
17.5 LR 24 XM27 594 412S 414S
17.5 R 25 XHA 637 416 426
19.5 LR 24 XM27 619 412S 414S
20.5 R 25 XHA 703 426 436
23.5 R 25 XHA 757 456
23.5 R 25 XMINE D2 794 456

Connection of Interrogation Lead

To install the laptop computer to the EMS:

1 Connect plug 100-A on the interrogation lead (892/

01066) to the RS232 port on the laptop.

2 Connect plug 100-3 on the interrogation lead to the

99-Y connector on the fuse/relay panel.

Fig 99.

Fig 100.

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 Section C - Electrics
Electronic Monitoring System
C164 EMS

C164 EMS

General
C164 (EMS 728/80077) is the latest level EMS system first
introduced in January 2006.

Important: Before attempting any diagnostic work on the

system, ensure that you have correctly identified the
software package. Please refer to System
Identification ( C-287).

Fig 102.

Note: For these diagnostic tools to work correctly, the Data

Link Adaptor (892/01174) must be connected (in
conjuction with the interrogation lead 71820237) between
the Diagnostic Connector and the PC, and the machine’s
ignition must be turned ON.

EMS Tools
Fig 101. Following is an outline of the available software tools and
how they are to be used.
With the introduction of this new type EMS there is a
requirement for advanced Standard Software Tools.
Service Tools
These tools are available within JCB Servicemaster 2.
They will come under the Large Wheeled Loader screen 1 Flash Loader program – to
shown: Fig 102. ( C-308). download the latest software files to
the EMS (these are called
Application files). This can be used
by double clicking the icon as
shown.

2 Set-up program – to enter the

machine Serial Number, Rolling
Radius etc. and Languages. This
program can be used by double
clicking the icon as shown

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 Section C - Electrics
Electronic Monitoring System
C164 EMS

Service Tools
3 Diagnostics program – to help
fault find on the machine. This
includes information about the 
Electronic Engine, Transmission

and the EMS. This program can be

used by double clicking the icon as
shown. 

4 Service History program – for


checking when the machine was

last maintained by a JCB Dealer.
This program can be used by 
double clicking on the icon as
shown.
 

5 Data Logger program – this

program logs various conditions of 
the machine before a failure, which
Fig 103.
will help in the diagnosis of certain
problems. This program can be
The icon 1 will appear as shown as confirmation that
selected by double clicking on the
the EMS system is communicating with the machine’s
icon as shown.
CAN-Bus network. If the icon is not present, check the
power to the DLA and the connections to the PC and
Flash Loader Program cab harness.

In order to download the latest software, the following has With the mouse, click this icon once. Doing this will fill
to be done: - the boxes A to E with information, providing the
information is already stored in the EMS.
1 Connect the DLA (Data Link Adapter), to the 9 Pin
Deutsch diagnostic connector in the cab and to the 5 With the icon now selected, the software can be
PC. Connecting the Interrogation downloaded. Click on the button indicated by 2 and
Lead ( C-316). browse for a file which should be in the following or
similar directory:
2 Turn the ignition to the first position so that the EMS
is powered up. a D:\Machine\Software\Updates/Earthmovers\
Large\Wheeled Loading Shovels\LWLS C164
3 Double click on the “Flash Loader” icon. EMS EMS\ 728-90269.vsf
Tools ( C-308).
Note: Ensure you are entering the correct and most up to
This icon is used to download the latest Software to date software.
the EMS. This Software is referred to as the
“Application code”. The icon launches a windows b Once the correct software has been selected,
application called the “Flash Downloader”. click “OK” in the window. The Software and its
directory path (see example above) will then be
4 The following “Flash Downloader” screen will appear: shown in the box labelled 3.

6 To start downloading the Software into the EMS, click

the “Start” button labelled 4 and then click “OK” to

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 Section C - Electrics
Electronic Monitoring System
C164 EMS
confirm. A blue bar will then continue to fill box 5 to
show how complete the downloading is. When this is  
full it will prompt you that the operation is complete.
Finally, click “OK” to complete. The EMS will then
reset itself and restart its normal operation.

7 Once this has done, close the “Flash Loader” window
by clicking the cross (x) in the top right hand corner.

8 The EMS will now have the new software installed.


Note: If you are just loading the latest software, you do not
need to re enter all the settings for the EMS (which can be
done using the following Set-up Program) as these will be
retained in memory from the last download.

Set-up Program
When a machine is being set-up for the first time, or a new
EMS unit has been fitted, the machine’s details and the
required language must be entered into the EMS.

This is achieved using the following procedure:

1 Double click on the Set-up icon on the desktop.

EMS Tools ( C-308).  
2 The following screen should then appear. Fig Fig 104. Set-up Screen 1
104. ( C-310).
a Select the ’Vehicle Set-up’ tab 6, if it does not start
with this automatically.

b Select the ‘Model Number’ 8 as you require, if this

has not appeared automatically.

Note: Once the serial Number has been entered into the
EMS it will locked and cannot be changed again.

c Enter the ‘Serial Number’ in box 9.

d With the mouse, click the ‘Next’ button 11 to

proceed to the ‘Options’ selection screen.

Note: If you just want to use this tool to read what settings
are in the EMS for the particular machine you are looking
at, just click this button. Once clicked, all the previously
entered data will be shown within this software tool. (That
is, assuming the EMS has been set up previously.)

e Once the ‘Next’ button identified by 11 has been

clicked, the following screen will then appear. This
screen can also have been selected by clicking on
the ‘Options’ tab 7. Fig 104. ( C-310).

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 Section C - Electrics
Electronic Monitoring System
C164 EMS
value entered in box 14 has elapsed, entering a time
in box 14 activates the feature.

The value to be entered can be any value required by

 the operator, however, the entered value must be
expressed in minutes.

 5 After the machine has been working/running for

specific periods of time, the EMS will display a
 warning to the operator that a service by a JCB
 Dealer is due. The specific time for the service
 request is entered into box 15, expressed as hours.

 6 In certain circumstances, machines can be set-up to
 be tracked by a satellite system and certain

parameters can be made visible via the Internet. This
 feature can be turned On by checking box 16.

 Note: This feature will not yet be available to the early

machines.

7 In order to track how many miles/kilometers the
machine has covered throughout its life, the EMS
 contains an optional feature to record this data. To
turn the feature ON, check box 17 ‘Odometer’. To turn
the feature OFF, toggle box 17 so the check mark is
removed and the box is left empty.
 
8 Certain machines have the option of having an
  Electric Emergency Steering Pump fitted to the
machine. If this is required then this option is toggled
and a check mark will be displayed in box 18.
Fig 105. Set-up Screen 2
9 On 456 Large Wheeled Loading Shovels, a different
3 Depending on which particular machine was selected type of Park Brake system is fitted. The option (box
at the start of the ‘Set-up procedure’, a list of tyre 19) will only be selectable when ‘456’ was selected
options will appear in box 12, that relate only to this from the Set-up tab. In all other cases the option will
particular machine range. be ‘ghosted out’ and cannot be selected.

Once the user has selected a tyre type from box 12, 10 The engine cooling fan is proportionally controlled by
the rolling radius for that tyre will automatically appear the EMS. Box 20 should be checked to turn the
in box 13. feature ON.

Note: If the tyre type fitted to the machine does not appear 11 The heated rear screen option can, once selected by
on the drop-down listing from box 12, the user can select checking the box, have a custom operating time value
‘Other’ from the list and manually input the required details. entered by the user into box 21.
However if this option is taken, the rolling radius for the tyre
will need to be manually input to box 13. 12 The Anti-stall feature:

4 If the machine requires an idle shutdown feature, To reduce the loading on the engine during cold
which means that the EMS will shut down the cranking, the anti-stall feature can be selected by
machine if the machine is in ‘neutral’ and the ‘time’

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 Section C - Electrics
Electronic Monitoring System
C164 EMS
checking the box. When selected this feature enables
the EMS to isolate the hydraulic load from the engine.

When selected the user can enter a custom value of

RPM (Revolutions Per Minute) into box 22. This will
be the Active Output Cut-off value.

13 The Reverse Fan option:

This option once selected can have custom time

values entered by the user for both the forward and
reverse running time of the fan. These values can be
entered at boxes 23.

14 Hydraulic Flow and Pressure Monitoring:


This option once selected can have custom values of 
flow measure in PPL (Pulse Per Litre) and Bar
entered by the user into boxes 24. 
15 Engine Specification: 

The Large Wheeled Loading Shovels are gradually

changing over from Mechanically Controlled Engines
to higher specification Electronically Controlled
Engines. The EMS incorporates a ‘Toggle Facility’,
boxes 25, by which it can monitor and control the
same features regardless of whether they are
interpreted as mechanical or electronic.

Note: It is important that you select the correct 'Engine

Specification' toggle for the machine. The way the EMS
 
translates the engine information depends on which
option, 'Electronic Engine' or 'Manual Engine', has been
Fig 106. Set-up Screen 3
selected. See Box 25.
17 To select the country of operation the user has to
16 All the unit settings displayed within the Set-up tool
select box 29 and scroll down the list to the relevant
have ‘Metric’ and ‘Imperial’ interpretations. The
country.
toggle, boxes 26, allow the user to switch between
them.
Once the country of operation has been selected from
the list, first, second and third language options will
To advance to the next screen to complete the ‘Set-up’, the
automatically appear in the areas 30, 31 and 32.
user now needs to click on the ‘Next’, box 28.
If all the settings have been entered for all the domains of
In order to review the previous page (the first ‘Set-up’
each tab, the user should now click on the button identified
screen) the user needs to click on the ‘Prev’, box 27.
as 34, ‘Transfer of Settings’, to save the information to the
EMS.
Once the user clicks on the ‘Next’, box 28 the following
Language screen will appear:
Note: Until the user clicks on Transfer of Setting button 34,
the collated information will remain on the laptop. No
transfer of data to the EMS will take place

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 Section C - Electrics
Electronic Monitoring System
C164 EMS
If the user has made a mistake or needs to change a 4 Each diagnostic aspect of the machine can be viewed
setting they have already entered onto this or either of the by making a selection from the menu toolbar 36 as
two preceding screens, they can, by clicking on the ‘Prev’ shown. Diagnostic Screen 2 ( C-313).
buttons 33 and 27, navigate back to the item they wish to
change.

Important: If the user returns to change any input

information or setting after the settings have been 
transferred to the EMS, the changes must be written to the
EMS by clicking on button 34 again. If the user fails to do
this the changes will not be written to the EMS.

Diagnostic Program
As an aid to fault diagnosis, the EMS contains a tool that
can diagnose the electrical circuits of the EMS, Electronic
Engine faults and parameters and also the fault codes and
parameters of the Smoothshift transmission.

In order to activate the diagnostic program proceed as


follows:
Fig 108. Diagnostic Screen 2
1 Double click on the ‘Diagnostic’ icon. EMS
Tools ( C-308). 5 This will then allow you to make a further selection
from the dropdown menu 37 that will appear on the
2 The following systems diagnostic screen will appear. left hand side of the screen.

To select an item from this menu, click the ‘tick box’

alongside the required item. This will open up a
window with the required information.

 6 Various information appertaining to the displayed

circuits, Voltages, pressures, states etc. will be
displayed in the window, and a key (38) to this
information will appear in the bottom left hand corner
of the screen.

Note: The information will be displayed in ‘real time’, which

means the information is accurately displayed and
instantly updated from the relevant source.

Fig 107. Diagnostic Screen 1

3 Before you can see any information, the ‘Green’ light

35 must be clicked on to enable the software to start
the diagnosis.

The software will start the process of communicating

on the CAN-Bus network with all the electronic
controllers.

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 Section C - Electrics
Electronic Monitoring System
C164 EMS
Engine Diagnosis Service History Program
Under the ‘Engine’ menu and ‘Fault codes’ selection, the A comprehensive history of the machines maintenance is
following screen appears. This screen is split into ‘Active contained in the EMS. To view this history proceed as
Fault Codes’ and any historic ones, ‘Previously Active follows:
Fault Codes’. Diagnostic Screen 3 ( C-314).
1 Double click on the ‘Service History’ icon. EMS
Tools ( C-308).

2 This will open up the following screen:




Fig 109. Diagnostic Screen 3

The ‘Active Fault Codes’ box A, shows all the current faults
that are on the machine with the ignition turned ON. These Fig 110. Service History Screen
errors will also be displayed on the EMS Liquid Crystal
Display, for example, E156. With this tool the Dealer can add and retrieve service
records created for an individual machine.
The ‘Previously Active Fault Codes’ box B, are all the faults
that were logged into the engine ECM, on all the previous To Start a Service Record, the dealer has to ‘Add a Service
occasions while the machine was running Record’ from the windows file menu as identified by A.
With this selection, the user can add all the known and
Note: Previously active fault codes will not be displayed on required information.
the EMS LCD. These faults can only be seen through use
of this service software tool. The file ‘Import’ and ‘Export’ selections will enable the
service records to be seen and saved to the Dealer’s PC
The operator can, if required, erase all the previously only.
active fault codes by clicking on the button identified as
item 39.

To exit the program, click on the small cross (X) in the top
right hand corner of the window.

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 Section C - Electrics
Electronic Monitoring System
C164 EMS

Data Logger Program Note: Other information, for example, ‘Engine Coolant’
and ‘Error Logs’ can be seen by clicking on the relevant
The Data Logger program enables the dealers to see tabs.
various statistics appertaining to a particular machine. This
information can be details of minimum and maximum An additional feature of this tool enables the user to
values of the machine recorded throughout the life of its produce a report for the machine.
current EMS unit.
To activate this facility proceed as follows:
To enable this program proceed as follows:
1 Select ‘File’ on the windows menu toolbar.
1 Double click on the ‘Data Logger’ icon. EMS
Tools ( C-308). 2 Select ‘Report’ from the File dropdown menu.

2 The following screen will appear. 3 This will produce a Report file as shown below.

Fig 112. Report File

4 This report can be saved or printed as required. To

achieve either of these select the required option from
the menu toolbar as illustrated at A above.

Fig 111. Data Logger Screen

3 To read the Data Logger information for the machine:

a Select ‘File’ from the windows menu toolbar.

b Select ‘Read Data’ from the File dropdown menu.

c The software will take a few seconds to gather the

required information.

d Once the required data has been retrieved, it will

be displayed as shown above. Data Logger
Screen ( C-315).

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 Section C - Electrics
Electronic Monitoring System
C164 EMS

Connecting the Interrogation Lead the single fastener on the panel cover and remove the
cover.
To install the laptop computer to the EMS:

1 Connect plug C on the USB Lead (718/20235) to the

USB port on the laptop. Connect the other end to the
Data link Adapter A (728/26500)

Note: It is possible to use a serial port lead (718/20236),

supplied with the diagnostic kit (892/01174), in place of the
USB port Lead.


Fig 114.
 

  

Fig 113.

2 Connect plug B on the interrogation lead (718/20237)

to the connector on the fuse/relay panel.

Note: The fuse/relay panel is located behind the operator’s

seat. To access the interrogation lead connector, release

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 Section C - Electrics

Alternator
S11524-7 Alternator

Removal and Replacement

Removal

Disconnect cables from rear of alternator, remove bolts

115A, 115B and 115C and withdraw unit from machine.

Replacement

Replace by reversing the removal sequence. Position the

alternator until belt deflection at is approximately 10mm (3/
8in) before tightening bolts 115B and 115C. It may be
necessary to slacken bolt 115C to allow full movement of
alternator. Tighten bolt 115A last of all.

Fig 115.

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 Section C - Electrics
Alternator
S11524-7 Alternator

Dismantling and Assembling When Assembling

When Dismantling Reverse the dismantling procedure, but note the following:

Remove capacitor 116-2 by disconnecting lead 116-L from Pack bearings with high melting point grease.
its terminal and removing retaining screw 116-1.
Ensure that slip ring faces are clean and smooth, using
Unscrew bolts 116-3 and remove regulator and brush box very fine glasspaper if required. Do not use emery cloth.
assembly 116-4.
Press slip rings and bearings as far as they will go onto the
Note: It is essential to remove the regulator and brush box shaft.
at this stage otherwise the brushes will be damaged.
Use resin cored solder when fitting slip-rings and rectifier.
Check the protruding length of the brushes 116-7. If this is Do not allow solder to build up on the face of the slip-rings.
less than 7 mm (0.28 in), the brushes must be renewed. Ensure that stator connecting wires will not touch against
the rotor.
Remove nut 116-10 and washer 116-11. Slide the pulley
116-12 and the impeller 116-13 off the Woodruff key 116- To ensure true running of the rotor, insert three 0.2 mm
15 and rotor shaft. feeler gauges between the stator and the rotor and tighten
screws 116-17 evenly in a diagonal sequence to the
Remove the Woodruff key 116-15 from the rotor shaft. specified torque setting.

Mark the relative positions of items 116-18, 116-19 and Lightly polish side faces of brushes to ensure free
116-28 to assist correct assembly. movement in brush box.

Remove terminal connections 116-16. Unscrew bolts 116- Table 14. Torque Settings
17 and remove the end shield 116-18 taking care that the Item Nm kgf m lbf in
stator connecting wires 116-A, 116-B and 116-C do not 1 2.9-4.1 0.3-0.4 26-36
get caught by the bracket. If necessary tap under each
3 1.6-2.3 0.16-0.24 14-20
fixing bolt lug with a mallet.
17 4.1-5.5 0.4-0.5 36-48
Unsolder rectifier terminal tags 116-X, 116-Y and 116-Z 20 1.4-2.0 0.14-0.2 13-18
and move the wires 116-A, 116-B and 116-C clear of the
rectifier. 23 2.4-2.9 0.25-0.3 21-26

Record the position of the stator output leads 116-A, 116- Table 15. Torque Settings
B and 116-C relative to the alternator fixing lugs and Item Nm kgf m lbf ft
remove the stator 116-19 by lifting it clear of the drive end 10 35-45 3.6-4.6 26-33
bracket 116-28 and rotor 116-25.

Remove screws 116-20 and remove rectifier 116-21.

Remove screws 116-23 and separate the rotor 116-25

(complete with bearings 116-24 and 116-27 from the drive
end bracket 116-28).

If required, remove the bearings and the slip-rings 116-29,

using a suitable puller.

Note: If the slip rings are removed, unsolder the

connections first.

C - 318 9803/4160-14 C - 318

 Section C - Electrics
Alternator
S11524-7 Alternator

Fig 116.

C - 319 9803/4160-14 C - 319

 Section C - Electrics
Alternator
A5524 Alternator

A5524 Alternator

Dismantling
For ease of re-assembly make relationship marks on the
stator stack and both end housings.

Remove drive pulley 117-1, fan 117-2 and fan washer 117-
3 then extract woodruff key 117-4 from the shaft and
withdraw spacer 117-5.

Remove suppression capacitor 117-6 from main output

terminals followed by the plastic end cover (three screws).

Remove two screws 117-7 and the Belville washers

holding the regulator, then disconnect the three Lucar
terminals 117-8, two on the brush box and one on the
negative rectifier.

Disconnect the remaining Lucar terminal from brush box

117-9. Remove the two screws and Belville washers and
lift out the brush box assembly.

Remove the four through-bolts 117-10, separate the drive

end housing assembly from the stator and slip ring end
housing assembly.

Remove the three bearing retainer plate screws 117-11

and remove the rotor from the drive end housing using a
gear puller or press.

Unsolder the three stator wires from the rectifier assembly

117-12 and separate the stator 117-13 from the slip ring
end housing 117-14.

C - 320 9803/4160-14 C - 320

 Section C - Electrics
Alternator
A5524 Alternator

Fig 117.

C - 321 9803/4160-14 C - 321

 Section C - Electrics
Alternator
A5524 Alternator

Inspection, Testing and Repair examine integral seals for any damage or distortion, renew
if necessary.
All parts should be thoroughly cleaned and inspected for
signs of wear, damage, corrosion and for deterioration of Press bearing into drive end housing applying pressure
insulation on windings. only to the outer race. Fit bearing retainer plate and tighten
the three screws to 1.69 Nm (15.0 lbf in) applying JCB
Lock and Seal to screw threads.
Rotor
Check rotor 117-15 for damage to the threads, keyway and
bearings. Carry out an insulation test and measure the
resistance of the windings (14.0 ohms + or - 0.2 ohms at
20° C (68° F) ambient. If the slip rings 117-16 are not
concentric and are badly worn or scored they must be
replaced as follows:

1 Carefully unsolder the leads from the slip ring pegs.

2 Remove the slip ring retaining screw and washer 117-

17 and pull the slip ring 117-16 away from the shaft.

3 Press on the new slip ring assembly after lining up the

rotor leads in the slip ring slots.

4 Fit screw and washer 117-17 and tighten to 2.3 Nm

(20 lbf in).

5 Wrap coil leads approx. 3 turns around slip ring pegs,

solder the joints and trim off any surplus peg.

Bearings

The bearings are sealed for life and cannot be serviced.

Slip ring end bearing - Removal and

Replacement
Remove slip ring 117-16 ( Rotor ( C-322)) and
deflector washer 117-18. Using a puller or press remove
bearing 117-19 followed by the spacer 117-20.

Examine leads, relocate into grooves, refit washer and

spacer. Press bearing 117-19 onto the shaft applying
pressure on the inner race only. Replace deflector washer
and refit slip ring assembly.

Drive end bearing - Removal and

Replacement
Remove the bearing from rotor using a puller or press
(note that the spacer has tapered side to bearing). Test
bearing for wear or roughness in operation, carefully

C - 322 9803/4160-14 C - 322

 Section C - Electrics
Alternator
A5524 Alternator

Slip ring end housing - Removing 29, then remove the screws 117-30, terminal and insulator
from inside the housing.
Rectifier
From inside the housing fit the terminal insulator with
Unsolder the D+ lead 117-31 from the auxiliary diode post
extension towards the bearing, fit lead terminal 117-31
D+.
with connecting lugs towards bearing and open ends
upwards, locate the squared section of the screw fully into
Note: Do not attempt to turn the round section of the
the insulator. From outside the housing fit the terminal
negative terminal as this bolt is splined to the negative
guard, Lucar terminal, Belville washer and nut then tighten
rectifier.
to 3.11 Nm (26.5 lbf/in).
From inside the housing remove the small nut 117-21, two
spring washers and the square ended barrel insulator 117- Brush holder assembly
22.
Check the brush holder and brushes for signs of damage
From outside the housing remove the small nut 117-23, or cracking. The minimum brush length is 10.0mm (0.393
Belville washer and Lucar terminal 117-24 from the in).
negative rectifier.
To renew brushes unsolder the brush lead at the terminal
Remove the rectifier 117-12 and retrieve the two insulating post and withdraw from the holder. Retain the insulating
washers 117-25, the square headed bolt 117-26 and the sleeving if serviceable.
remaining square headed barrel insulator.
Fit the sleeving to the new brush leads and thread through
Refitting rectifier the center of spring 117-32 and small exit hole.

From inside the housing, locate the square headed bolt Pull on the brush lead so that a maximum of 15.0mm
117-26 and barrel insulator. From outside the housing, (0.589 in) of the brush is protruding, make one complete
place an insulating washer 117-25 on the bolt. turn of the lead around the terminal post and re-solder.

Fit the insulating washer to the negative terminal bolt on Stator and housing
the rectifier and place in the housing.
Check the stator windings to ensure that the wires are not
Fit Lucar terminal, Belville washer and nut to square obviously burned, broken or the insulation damaged. Carry
headed rectifier retaining bolt 117-26. out an insulation test using a 110 volt - 15 watt test lamp
between each of the three cables and the stator in
From inside the housing correctly locate the barrel sequence.
insulator 117-22 on negative terminal bolt, refit the two
spring washers and nut 117-21 then tighten to 3.11 Nm
Check the resistance between each pair of leads.
(26.5 lbf in).

Tighten the rectifier mounting bolt to 2.00 Nm (17 lbf in) Re-assembly
ensuring that the Lucar terminal 117-24 has adequate
clearance from the auxiliary diode post when leads are Re-assemble by reversing the order of dismantling,
refitted. checking that all connections are well made and that all
insulations are in good condition.
Solder the D+ lead onto the auxiliary diode post D+.

To remove and refit D+ and F- leads

Do not attempt to turn screws from inside the housing.

From outside the housing remove the nut 117-27, Belville

washer, Lucar terminal 117-28 and the terminal guard 117-

C - 323 9803/4160-14 C - 323

 Section C - Electrics
Alternator
A5524 Alternator

Fig 118.

C - 324 9803/4160-14 C - 324

 Section C - Electrics
Alternator
A5524 Alternator

Testing 2 Check that the lead to terminal 118D (D+) - (wire No.
419 small Lucar connector) and the lead to terminal F
Fault (F-) -(wire No. 6001 - large Lucar connector) have not
been crossed. If wiring is correct the alternator is
No charge warning light does not come on when faulty.
starter switch turned to IGN.
Rectifier testing
No charge warning light glows dimly when starter
switch turned to IGN. Main diodes

1 Check alternator, regulator 118R and battery Check the diodes using an Ohmmeter or 24 volt power
connections. supply and a low wattage lamp.

2 Check warning light by removing the lead from If a diode is found to be faulty, the complete assembly must
terminal 118D (D+) and connecting it to terminal 118F be replaced.
(F-). If warning light is OFF, the bulb or the machine
wiring is faulty. If the warning light is ON, proceed to To test, connect one probe to terminal 118B (B-) and the
step 4. other probe to the three diode connections 118M in turn.
Reverse the probes and repeat this check. If using an
Note: Terminal 118F is the LARGE spade connector. DO Ohmmeter, the check should show a low resistance in one
NOT TOUCH THE SMALL TERMINAL (AC) OR THE direction and a very high resistance when the probes are
WIRE CONNECTION NEXT TO IT. reversed.

3 Check the warning light bulb by removing it and Repeat the procedure using terminal 118C and the three
checking with a circuit tester. diode connections 118M.

4 Remove regulator screws and ease back the Auxiliary diodes

regulator 118R as shown.
Check the auxiliary diodes by connecting one probe on the
5 Check brush contact with slip-ring and rotor circuit. 118N terminal and the other probe on the three soldered
main diode connections 118M in turn, and then reverse the
6 Remove the lead from terminal 118D (D+) and probes and repeat this check. If using an Ohmmeter, the
connect it to the following terminals in turn to isolate check should show a low resistance in one direction and a
the faulty area. If the warning light illuminates, the very high resistance when the probes are reversed.
following table indicates the fault.
Note: A low resistance both ways = short circuit diode. A
high resistance both ways = open circuit diode. If using a
Terminal fault power supply and lamp, the bulb must light in one direction
E Wiring D to E only.

A Regulator
Testing
G Rotor circuit or brushes
F (F-)Wiring G to F Before testing alternator, carry out charging circuit checks
1 and 2.
Fault
Failure of the alternator to charge the battery may be
No charge warning light does not go out when engine caused by one of the following conditions. These are listed
running. in approximate order of probability.

1 Check alternator, regulator 118R and battery 1 Defective regulator.

connections. Check fan belt tension.
2 Dirty slip rings or worn slip ring brushes.

C - 325 9803/4160-14 C - 325

 Section C - Electrics
Alternator
A5524 Alternator
3 Defective Rectifier.

4 Defective surge protection diode.

5 Open or short circuited field (rotor) winding.

6 Open or short circuited power (stator) windings.

Regulator Check
On 18ACR alternator remove end cover and temporarily
connect the regulator field to earth as at 119X or 119Y,
according to the type of regulator fitted:

14TR Regulator (119X) Regulator case to alternator

frame.

8TR Regulator (119Y) Green wire to alternator frame.

On A115 alternator, insert a conductive probe through a

slot in the end cover and earth the regulator case to the
alternator frame.

On AC5R and AC5HER alternator ( Fig

120. ( C-326)), connect ‘F’ terminal on brush box to
negative (-) terminal.

Connect test meter (see Tool Detail Reference

Section C - Electrics ( 1-10)) in circuit, using a dummy
alternator connector as shown in Charging Circuit Check
2.
Fig 119.
Run the engine at 2000 rev/min. switch on all lights and
auxiliaries and check the ammeter reading.

If the ammeter now indicates the maximum rate of charge,

the alternator is in good order but the regulator is defective.
If the ammeter continues to show a low reading, remove
the alternator for further testing.

On 18 ACR alternators, disconnect the surge protection

diode 119A and repeat the test. If the ammeter reading is
now satisfactory, the diode is defective.

Fig 120.

C - 326 9803/4160-14 C - 326

 Section C - Electrics
Starter Motor
426 and 436 Machines

Starter Motor
426 and 436 Machines

Removal and Replacement Assembly

Disconnect cables and remove battery. Remove cables Soak new bushes 122-32 and 122-34 in clean warm
from main starter terminal and solenoid terminal. Unscrew engine oil for 24 hours before fitting.
three securing nuts and remove starter motor.
Align crosspin 122-C with the notches in the brake shoes
Replace by reversing the removal sequence. 122-28 before assembling brush carrier and back plate to
motor yoke. Ensure that brushes 122-14A are correctly
located in the insulated brush boxes.
Dismantling
Smear drive shaft splines and operating collar bearing
Note: Dismantle only to item 122-34 unless the field
surface with JCB MPL Grease before assembly. Assemble
windings are to be renewed. Test the windings electrically
operating fork 122-19 with curved face toward the
before removing them from the motor yoke 122-15.
armature.
Using a slotted steel tube, displace ring 122-23 to permit
Set the movement of drive pinion 122-24 by connecting a
withdrawal of ring 122-22.
6v battery and switch as shown. Operate switch and check
dimension 121-D. Adjust to 0.13-1.14mm (0.005-0.045in.)
Allow brake shoes 122-28 to remain in the end plate 122-
by slackening locknut 122-17 and rotating eccentric pin
11 unless requiring renewal.
122-18 as necessary. Re-tighten locknut.

Servicing and Renewal

Renew brushes 122-14 and 122-14A if their length is less
than 8mm (0.3in.).

Clean the commutator 122-A. If individual copper bars are

burned or eroded the armature has broken windings and
must be renewed. Otherwise polish with fine grade glass
paper (not emery). Renew armature if commutator
diameter is 38mm (1.5in.) or less.

Check the field windings for open circuits by connecting a

multimeter set to measure resistance (see C-27))
between the stud terminal 122-B and each positive brush
122-14A in turn. A high or infinity reading indicates an
open circuit. Similarly, connect the meter between brushes Fig 121.
122-14A and the motor yoke 122-15. Any reading other
than infinity indicates a short circuit between the coils and
the yoke. Renew the coils as necessary, removing screws
122-36 with a pole shoe screwdriver C50 (obtainable from
Lucas dealers).

Check bronze bushes 122-32 and 122-34 for wear.

C - 327 9803/4160-14 C - 327

 Section C - Electrics
Starter Motor
426 and 436 Machines

Fig 122.

C - 328 9803/4160-14 C - 328

 Section C - Electrics
Starter Motor
446 Machines

446 Machines

Removal and Replacement Cleaning

Removal The drive, armature and field windings should not be
cleaned with any degreasing agents since this would
1 Open the battery isolator and disconnect the battery remove lubrication and damage insulation. All parts should
leads from the terminals. be cleaned with mineral spirits and a brush. The drive can
be wiped with a clean cloth.
2 Remove cables from main starter terminal and
solenoid terminal. If the commutator is dirty it may be cleaned with No. 00
sandpaper. NEVER USE EMERY CLOTH TO CLEAN
3 Unscrew three securing nuts and remove starter THE COMMUTATOR.
motor.
Assembly
Replacement
1 Inspect the brushes for wear. If the brushes show
Replacement is the reverse of the removal sequence. excessive wear when compared with a new brush,
renew them.
Dismantling
2 Check by hand to ensure brush springs are giving firm
Note: Do not remove the field windings 5 from the motor contact between brushes and commutator.
yoke unless they are to be renewed. Test the windings
electrically before removing them. 3 All bearings, wicks and oil reservoirs should be
saturated with an SAE No. 20 oil. Smear drive shaft
1 Mark the relative positions of solenoid 14, lever with JCB MPL grease. Assemble operating lever with
housing 9, nose housing 12 and motor yoke so that the longest continuous edge towards the armature.
they can be assembled in the same positions.
4 Reassemble the starter motor in the reverse order of
2 Disconnect field coil connecter from solenoid motor dismantling.
terminal and ground return lead 6 from solenoid.

3 Remove bolts from commutator end cap 2 and

remove end cap.

4 Remove attaching screws to separate brush holder

17 from motor yoke.

5 Remove attaching bolts to separate nose housing 12

and motor yoke from lever housing 9.

6 Remove pinion stop.

7 Remove armature and clutch assembly from lever

housing.

8 Separate solenoid from lever housing by pulling

apart.

C - 329 9803/4160-14 C - 329

 Section C - Electrics
Starter Motor
446 Machines

Setting the Drive Pinion Clearance (446) 3 Push pinion 123-4 and drive 123-5 back towards the
commutator end, to eliminate any slack.
1 Make electric connections as shown in Fig
123. ( C-330). 4 Measure distance 123-D. The correct distance should
be between 8.3 mm and 9.9 mm (0.33 in - 0.39 in).
2 Momentarily flash a jumper lead from ground return
terminal 123-1 to terminal MTR2 (see Fig 5 Adjust the clearance if required by removing plug
123. ( C-330)). The drive will shift into the cranking 123-6 in lever housing 123-7 and turning shaft nut
position and remain so until battery 123-3 is 123-8. (Clockwise to decrease the clearance and
disconnected. anti-clockwise to increase the clearance.)

Fig 123.

C - 330 9803/4160-14 C - 330

 Section C - Electrics
Starter Motor
446 Machines

No Load Test (446) position from solenoid battery terminal 124-8 to

solenoid switch terminal 124-9.
Before carrying out these tests check the condition of the
batteries (see Testing ( C-32)) and ensure that all 3 Close the switch and compare rpm, current and
connections are clean and tight. voltage readings as specified in Performance
Figures, Opposite.
To prevent the engine from starting during the tests,
ensure that the ESOS solenoid is disconnected. Note: It is not necessary to obtain the exact voltage
specified in the table as an accurate interpretation can be
made by recognising that if the voltage is slightly higher,
the rpm will be proportionally higher, with the current
remaining essentially unchanged.

4 If the exact voltage is needed then a variable

resistance should be connected across the terminals
of one of the batteries.

Test Results

1 Rated current draw and no-load speed indicate

normal condition of the starter motor.

2 High current draw and low free speed indicate:-

a Too much friction - Tight, dirty, worn bearings;

bent armature shaft or loose pole shoes, allowing
armature to drag.

Fig 124. b Shorted armature - This can be further checked

Key after disassembly.
1 Voltmeter
c Grounded armature or fields - Can also be
2 Motor Terminal checked after disassembly.
3 Ground Return Terminal
3 Failure to operate with high current draw indicates:-
4 Tachometer
5 Motor a A direct ground in the terminal or fields.
6 Ammeter
b ‘Frozen’ bearings.
7 Switch
8 Solenoid Battery Terminal 4 Failure to operate with no current draw indicates:-
9 Solenoid Switch Terminal
a Open field circuit - This can be checked after
10 Solenoid disassembly by inspecting the terminal
11 Battery connections and tracing the circuit with a lamp.

1 Connect voltmeter 124-1 from motor terminal 124-2 b Open armature coils - Inspect the commutator for
to ground return terminal 124-3 and use a tachometer badly burned bars after disassembly.
124-4 to indicate armature speed.
c Broken brush springs, worn brushes, high
2 Connect motor 124-5 and ammeter 124-6 in series insulation between the commutator bars or other
with the batteries and switch 124-7 in the ‘open’ causes which would prevent good contact
between the brushes and the commutator.

C - 331 9803/4160-14 C - 331

 Section C - Electrics
Starter Motor
446 Machines
5 Low no-load speed and low current draw indicate:- 2 Motor Running free @ 23 Volts (very slight sparking
at bushes).
a High internal resistance due to poor connections,
defective leads, dirty commutator plus items 4a,
Amps: 60 - 75
4b and 4c.
RPM: 6300 - 8400
6 High free speed and high current draw indicate a
shorted field. If this is suspected, replace the field coil 3 Locked Torque
assembly and re-test.
Amps: 500
Performance Figures
Torque: 26 lb/ft (minimum).
1 No Load Test Volts: Approx. 3.0 (at terminals on motor).

Volts Min Max. Min. RPM Max. 4 PULL-IN and HOLD-IN Coils
Amps. Amps. RPM
23 60 75 6300 8400
Combined Current Draw with 20 Volts applied.
Amps: 45 - 54

Fig 125.

C - 332 9803/4160-14 C - 332

Section E

Hydraulics
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-12



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section E - Hydraulics

Page left intentionally blank

E-0 9803/4160-12 E-0

 Section E - Hydraulics

Contents Page No.

Technical Data
426 Machines up to Serial number 532099 ............................................ E - 1
Pump ................................................................................................. E - 1
Loader Valve ..................................................................................... E - 1
436, 446 Machines ................................................................................. E - 3
Primary Pump .................................................................................... E - 3
Secondary Pump ............................................................................... E - 3
Loader Valve ..................................................................................... E - 3
Smoothshift Machines: 426 from serial number 532100,
436 from serial number 533692 .............................................................. E - 5
Pump ................................................................................................. E - 5
Loader Valve ..................................................................................... E - 5
Auxiliary Relief Valves (A.R.V.) .......................................................... E - 6
426 from Serial Number 532500, 436 from Serial Number 534200 ....... E - 7
Pump ................................................................................................. E - 7
Loader Valve ..................................................................................... E - 7
Auxiliary Relief Valves (A.R.V.) .......................................................... E - 8
426 from Serial Number 532847, 436 from Serial Number 534469 ..... E - 10
Pump ............................................................................................... E - 10
Loader Valve ................................................................................... E - 10
Auxiliary Relief Valves (A.R.V.) ......................................................... E - 11
Accumulators ................................................................................... E - 12
426 from M1231500, 436 from M1305000 ........................................... E - 13
Pump ............................................................................................... E - 13
Loader Valve ................................................................................... E - 13
Auxiliary Relief Valve (ARV) Settings .............................................. E - 14
Accumulators ................................................................................... E - 15

Basic Operation
General Description .............................................................................. E - 16
426 .................................................................................................. E - 16
436 .................................................................................................. E - 16
Valve Block Tie-Rods ...................................................................... E - 16
Introduction to Hydraulic Schematic Symbols ...................................... E - 17
General (Basic and Functional Symbols) ........................................ E - 17
Control Valves ................................................................................. E - 21
Example of Schematic Circuit ......................................................... E - 22

Circuit Diagrams
426 to M531203, 436 to M533195 ....................................................... E - 23
426 with 4-Ram Loader ................................................................... E - 23
426 with Z-Bar Loader ..................................................................... E - 25
436 with 4-Ram Loader ................................................................... E - 27
436 with Z-Bar Loader ..................................................................... E - 29
426 from M531204, 436 from M533196 ............................................... E - 31
426 with 4 Ram Loader ................................................................... E - 31
426 with Z-Bar Loader ..................................................................... E - 33
436 with 4-Ram Loader ................................................................... E - 35
436 with Z-Bar Loader ..................................................................... E - 37
Smoothshift Machines (426 from M532100, 436 from M533692) ........ E - 39
426, 436 with 4 Bar Loader ............................................................. E - 39
426, 436 with Z-Bar Loader ............................................................. E - 41
436 from M534200 (Tier II) .................................................................. E - 43
436 HT ............................................................................................. E - 43
436 ZX ............................................................................................. E - 45

E-i E-i
 Section E - Hydraulics
Contents

Contents Page No.

426 from M532847 ............................................................................... E - 47
426 HT ............................................................................................. E - 47
426 ZX ............................................................................................. E - 49
436 from M534469 ............................................................................... E - 51
436 HT ............................................................................................. E - 51
436 ZX ............................................................................................. E - 53
426 from M1231500, 436 from M1305000 ........................................... E - 55
Schematic Diagrams ....................................................................... E - 55

Circuit Descriptions
Pump Operation ................................................................................... E - 63
Pump Pressure/Flow Regulator Valves ................................................ E - 65
Start Up ........................................................................................... E - 65
Hydraulic Service Operated ............................................................ E - 65
Minimum Flow/Maximum Pressure ................................................. E - 65
Start Up Valve ....................................................................................... E - 67
Loader Valve ......................................................................................... E - 69
Loader Valve - Arms Raise/Lower ........................................................ E - 71
Loader Valve - Shovel Float ................................................................. E - 73
Loader Valve - Shovel Tip (4-Ram Loader) .......................................... E - 75
Loader Valve - Shovel Crowd (4-Ram Loader) ..................................... E - 77
Loader Valve - Shovel Tip (Z-bar Loader) ............................................ E - 79
Loader Valve - Shovel Crowd (Z-bar Loader) ....................................... E - 80
Compensator Spool - Operation 1 ........................................................ E - 81
Compensator Spool - Operation 2 ........................................................ E - 83
Auxiliary Services ................................................................................. E - 85
Servo Pressure Regulating Valve ......................................................... E - 87
Neutral Standby Pressure ............................................................... E - 87
Service Operating ............................................................................ E - 87
Automatic Carry Control System (ACCS) ............................................. E - 89
Introduction ...................................................................................... E - 89
Hydraulic Circuit .............................................................................. E - 90
Operation ......................................................................................... E - 91
Maintenance Safety ......................................................................... E - 91
ACCS 426 from M1231500, 436 from M1305000 ................................ E - 92
General ............................................................................................ E - 92
Circuit Descriptions ......................................................................... E - 92
Maintenance Safety ......................................................................... E - 97
Electronic Emergency Steering ............................................................ E - 98
General ............................................................................................ E - 98

Fault Finding
Hydraulic Fault Finding ......................................................................... E - 99

Service Procedures
Hydraulic Contamination .................................................................... E - 100
Hydraulic Fluid Quality .................................................................. E - 100
Effects of Contamination ............................................................... E - 100
Cleaning Operation ....................................................................... E - 100
Contaminant Standards ................................................................. E - 101
Filters ............................................................................................. E - 101
Venting the Hydraulic Pressure .......................................................... E - 102
426 from M1231500, 436 from M1305000 .................................... E - 102
Automatic Carry Control System Venting ...................................... E - 102

E - ii E - ii
 Section E - Hydraulics
Contents

Contents Page No.

Connecting and Disconnecting Hydraulic Hoses ................................ E - 103
Connecting the Hoses ................................................................... E - 103
Disconnecting the Hoses ............................................................... E - 103
`Positional Type' Hydraulic Adaptors .................................................. E - 104
Fitting Procedure ........................................................................... E - 104
Flow and Pressure Tests .................................................................... E - 105
Main Pump - 426 Machines ........................................................... E - 105
Main Pump - 436, 446 Machines ................................................... E - 107
Pressure Testing the Loader Valve A.R.V.’s Using a Hand Pump .. E - 110
Tandem Pumps .............................................................................. E - 112
Servo Pressure - Tandem Pumps .................................................. E - 114
Steering Relief Valve ...................................................................... E - 115
Two-Stage Shovel Ram (Head Side) .............................................. E - 116
Idle Control Setting .............................................................................. E - 118
426, 436 Machines ......................................................................... E - 118
Hydraulic Cooling Fan Setting ............................................................ E - 120
436 Machines to M1305000 .......................................................... E - 120
Reversing Fan Software ................................................................ E - 122
Programming the Reversing Fan Frequency and Duration ........... E - 122
426 Machines from M1231500, 436 Machines from M1235000 ... E - 123
Emergency Steering (Electronic) ....................................................... E - 125
Checking/Adjusting the System Pressure ..................................... E - 125
Automatic Carry Control System (ACCS) ........................................... E - 127
Accumulators ................................................................................. E - 127
Dismantling, Inspection and Assembly .......................................... E - 131

Pumps
426 Machines Removal and Replacement ......................................... E - 134
When Removing ............................................................................ E - 134
When Replacing ............................................................................ E - 134
436 Machines Removal and Replacement (Primary) ......................... E - 135
When Removing ............................................................................ E - 135
When Replacing ............................................................................ E - 135
436 Machines Removal and Replacement (Secondary) .................... E - 137
When Removing ............................................................................ E - 137
When Replacing ............................................................................ E - 137
Tandem Pumps - 426, 436 ................................................................. E - 139
General .......................................................................................... E - 139
Removal and Replacement ........................................................... E - 139
Replacing the Pressure/Flow Regulator ............................................. E - 141
Renewing Drive Shaft Seal ................................................................. E - 142
Dismantling, Inspecting and Assembly ............................................... E - 143
Dismantling .................................................................................... E - 143
Inspecting ...................................................................................... E - 143
Assembly ....................................................................................... E - 143

Emergency Steering
426 from S/N 532847, 436 from S/N 534469 ..................................... E - 145
Removal and Replacement ........................................................... E - 145

Cooling Fan Motor

436 from M534200 ............................................................................. E - 147
Removal and Replacement ........................................................... E - 147
Replacement ................................................................................. E - 147
Dismantling, Inspection and Assembly .......................................... E - 148

E - iii E - iii
 Section E - Hydraulics
Contents

Contents Page No.

426 from 1231500, 436 from 1305000 .............................................. E - 152
Removal ........................................................................................ E - 152
Replacement ................................................................................. E - 153
Uni-Directional Motor ..................................................................... E - 154
Bi-Directional Motor ....................................................................... E - 158

Rams
Precautions During Use ...................................................................... E - 162
Installation ..................................................................................... E - 162
Caution During Use ....................................................................... E - 162
Maintenance, Inspection Points .................................................... E - 162
Typical Ram ........................................................................................ E - 164
Dismantle and Assembly ............................................................... E - 164
JCB Ram Sealing Procedure ........................................................ E - 167
Piston Head Retention .................................................................. E - 169
Z Rams ............................................................................................... E - 170
Z Ram ............................................................................................ E - 170
436ZX Ram ........................................................................................ E - 172
Dismantling the piston rod from cylinder tube ............................... E - 172
Dismantling the piston rod ............................................................. E - 174
Removing the piston seals ............................................................ E - 176
Removing the cylinder head seals ................................................ E - 177
Assembling the piston seals .......................................................... E - 180
Assembling the cylinder head seals .............................................. E - 183
Assembly of piston rod with cushion ring on the piston rod side ... E - 185
Assembly of piston rod with cushion ring on the piston rod
and cylinder bottom side ............................................................... E - 188
Assembly of piston rod in cylinder tube ......................................... E - 192

E - iv E - iv
 Section E - Hydraulics

Technical Data
426 Machines up to Serial number 532099

Pump

Type Rexroth. Tandem variable displacement axial piston

Ref A20VO60 DFR1/10R-NSD24K01-S1296
Standby flow 5 litres/min 1.1 UK gal/min 1.3 US gal/min
Full flow at 2200 rev/min 220 litres/min 48.4 UK gal/min 58.1 US gal/min
Flow at max. pressure (220 bar) 5 litres/min 1.1 UK gal/min 1.3 US gal/min

Loader Valve

Type Rexroth, stacked directional control, model MP-22.

Services Operated
Spool 1 (LV1) Loader arms
Spool 2 (LV2) Shovel
Spool 3 (LV3) (optional) Auxiliary (Quickhitch)
Spool 4 (LV4) (optional) Auxiliary (Clam)

Relief Valve Operating Pressures bar kgf/cm 2 lbf/in2

System control pressure (pump relief valve) 220 224 3190
Standby pressure (pump relief valve) 27 27.5 391.5
Auxiliary Relief Valves (A.R.V.)
Lift ram, head side 345 352 4985
Shovel ram, head side (1st stage) (1) 80 81.6 1160
Shovel ram, head side (2nd stage) 225 230 3262
Shovel ram, rod side 248 253 3596
Servo 27-35 27.5-35.6 391.5-508
Brake (non-adjustable) (max) 80 81.6 1160
Steer relief pressure (at ram) 175 178.5 2537.5
Steer relief pressure (at pump) 190 193.8 2755
Idle control pressure 140 142.8 2030 (up to 1150-1250 rev/min)

(1) Not fitted on Z-bar machines.

By-pass Pressures bar kgf/cm 2 lbf/in2

Filter 1.5 1.53 22

E-1 9803/4160-12 E-1

 Section E - Hydraulics
Technical Data
426 Machines up to Serial number 532099

By-pass Pressures bar kgf/cm 2 lbf/in2

Oil Cooler 3.0 3.06 44

Capacities Litres UKgal US gal

Hydraulic tank 164 36.1 43.4

Rams Bore Rod Dia. Stroke

mm in mm in mm in
Shovel Ram 100 3.9 60 2.4 1056 41.6
Lift Ram 110 4.3 60 2.4 821 32.3
Steer Ram 90 3.1 50 2.0 312 12.3

Filter
Filtration Size 10 Micron
By pass Setting 1.5 bar
Suction Strainer Size 140 Micron

E-2 9803/4160-12 E-2

 Section E - Hydraulics
Technical Data
436, 446 Machines

436, 446 Machines

Primary Pump

Type Rexroth. Variable displacement axial piston

Ref AV10VO 71DFR 1/31 RPS C2 NOO
Standby flow 5 litres/min 1.1 UK gal/min 1.3 US gal/min
Full flow at 2200 rev/min 156 litres/min 34.3 UK gal/min 41.2 US gal/min
Flow at max. pressure (220 bar) 5 litres/min 1.1 UK gal/min 1.3 US gal/min

Secondary Pump

Type Rexroth. Variable displacement axial piston

Ref AA10VO 45OFR 1/50L PSC 11NOO-50420
Standby flow 3 litres/min 0.7 UK gal/min 0.8 US gal/min
Full flow at 2200 rev/min 99 litres/min 21.8 UK gal/min 26.1 US gal/min
Flow at max. pressure 3 litres/min 0.7 UK gal/min 0.8 US gal/min

Loader Valve

Type Rexroth, stacked directional control, model MP-22.

Services Operated
Spool 1 (LV1) Loader arms
Spool 2 (LV2) Shovel
Spool 3 (LV3) (optional) Auxiliary (Quickhitch)
Spool 4 (LV4) (optional) Auxiliary (Clam)

Relief Valve Operating Pressures bar kgf/cm2 lbf/in 2

System control pressure (main pump relief valve) 245 - 255 250 - 260 3552 - 3697
Standby pressure (main pump relief valve) 27 27.5 391.5
System pressure (secondary pump return valve) 155 - 165 158 - 168 2247 - 2392
Standby pressure (secondary pump) 25 25.5 362.5
Auxiliary Relief Valves (A.R.V.)
Lift ram, head side 345 352 4985
Shovel ram, head side (1st stage) (1) 80 81.6 1160
Shovel ram, head side (2nd stage) 225 230 3262
Shovel ram, rod side (HT) 248 253 3596
Shovel ram, rod side (ZX) 125 127 1813
Servo 27-35 27.5 - 35.6 391.5 - 508

E-3 9803/4160-12 E-3

 Section E - Hydraulics
Technical Data
436, 446 Machines

Relief Valve Operating Pressures bar kgf/cm2 lbf/in 2

Brake (non-adjustable) 80 81.6 1160
Steer relief pressure (at ram) 175 178.5 2537.5
Steer relief pressure (at pump) 190 193.8 2755
Idle control pressure 25 25.5 362.5 (Secondary pump remains at
Standby up to 1150-1250 rev/min)

(1) Not fitted on Z-bar machines

By-pass Pressures bar kgf/cm 2 lbf/in2

Filter 1.5 1.53 22
Oil Cooler 3.0 3.06 44

Capacities Litres UKgal US gal

Hydraulic tank 181 39.8 47.9

Rams Bore Rod Dia. Stroke

mm in mm in mm in
Shovel Ram 110 4.3 60 2.4 1056 41.6
Lift Ram 130 5.1 70 2.8 814 32.0
Lift Ram (446) 140 5.5 75 2.9 814 32.0
Steer Ram 80 3.1 50 2.0 312 12.3

Filter
Filtration Size 10 Micron
By pass Setting 1.5 bar
Suction Strainer Size 140 Micron

E-4 9803/4160-12 E-4

 Section E - Hydraulics
Technical Data
Smoothshift Machines: 426 from serial number 532100, 436 from serial number 533692

Smoothshift Machines: 426 from serial number 532100, 436 from serial
number 533692

Pump

Type Rexroth. Tandem variable displacement axial piston

Ref A20VO60 DFR1/10R-NSD24K01-S1296

Pump 1 litres/min UK gal/min US gal/min

Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (220 bar) 5 1.1 1.3

Pump 2
Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (160 bar) 5 1.1 1.3

Loader Valve

Type Rexroth, stacked directional control, model MP-22.

Services Operated
Spool 1 (SV) Priority Steer
Spool 2 (LV1) Loader arms
Spool 3 (LV2) Shovel
Spool 4 (LV3) Auxiliary (Quickhitch)
Spool 5 (LV4) Auxiliary (Clam) (optional)

Relief Valve Operating Pressures bar kgf/cm 2 lbf/in2

Pump 1
Standby pressure (pump compensator valve) 27 27.5 391.5
System control pressure (pump relief valve) 245 - 255 250 - 260 3552 - 3697
Pump 2
Standby pressure (pump compensator valve) 25 25.5 362.5
System control pressure (pump relief valve) 155 - 165 158 - 168 2247 - 2394

E-5 9803/4160-12 E-5

 Section E - Hydraulics
Technical Data
Smoothshift Machines: 426 from serial number 532100, 436 from serial number 533692

Auxiliary Relief Valves (A.R.V.)

Operating Pressures bar kgf/cm 2 lbf/in2

Lift ram, head side 345 352 4985
HT Shovel ram, head side 125 127 1812
ZX Shovel ram, head side 125 127 1812
Shovel ram, rod side 260 265 3770
Servo 27-35 27.5-35.6 391.5-508
Brake (non-adjustable) 80 81.6 1160
Steer relief pressure (at ram) 175 178.5 3262
Steer relief pressure (at pump) 190 193.8 2755
Idle control pressure 25 25.5 362.5

By-pass Pressures bar kgf/cm 2 lbf/in2

Filter 1.5 1.53 22
Oil Cooler 3.0 3.06 44

Capacities Litres UKgal US gal

Hydraulic tank 181 39.8 47.9
Hydraulic Tank (446) 173 38.0 45.8

Rams Bore Rod Dia. Stroke

mm in mm in mm in
Shovel Ram (HT 426) 100 3.9 60 2.4 1056 41.6
Shovel Ram (HT 436) 110 4.3 65 2.6 1056 41.6
Shovel Ram (ZX 426) 130 5.1 70 2.8 575 22.6
Shovel Ram (ZX 436, 446) 160 6.3 80 3.1 530 20.9

Lift Ram (426) 130 5.1 70 2.8 814 32.0

Lift Ram (436) 130 5.1 70 2.8 814 32.0
Lift Ram (446) 140 6.3 75 3.1 744 29.3

Steer Ram 80 3.1 50 2.0 312 12.3

Filter
Filtration Size 10 Micron
By pass Setting 1.5 bar
Suction Strainer Size 140 Micron

E-6 9803/4160-12 E-6

 Section E - Hydraulics
Technical Data
426 from Serial Number 532500, 436 from Serial Number 534200

426 from Serial Number 532500, 436 from Serial Number 534200

Pump

Type Rexroth. Tandem variable displacement axial piston

Ref A20VO60 DFR1/10R-NSD24K01-S1296

Pump 1 litres/min UK gal/min US gal/min

Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (220 bar) 5 1.1 1.3

Pump 2
Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (160 bar) 5 1.1 1.3

Loader Valve

Type Rexroth, stacked directional control, model MP-22.

Services Operated
Section 1 (SV) Priority Steer
Section 2 (LV1) Loader arms
Section3 (LV2) Shovel
Section 4 (LV3) Auxiliary (Quickhitch)
Section 5 (LV4) Auxiliary (Clam) (optional)

Relief Valve Operating Pressures bar kgf/cm 2 lbf/in2

Pump 1
Standby pressure (pump compensator valve) 27 27.5 391.5
System control pressure (pump relief valve) 245 - 255 250 - 260 3552 - 3697
Idle control pressure 45 45.9 652.7
Pump 2
Standby pressure (pump compensator valve) 25 25.5 362.5
System control pressure (pump relief valve) 155 - 165 158 - 168 2247 - 2394
Idle control pressure 45 45.9 652.7

E-7 9803/4160-12 E-7

 Section E - Hydraulics
Technical Data
426 from Serial Number 532500, 436 from Serial Number 534200

Auxiliary Relief Valves (A.R.V.)

Operating Pressures bar kgf/cm 2 lbf/in2

Lift ram, head side 345 352 4985
HT Shovel ram, head side 125 127 1812
ZX Shovel ram, head side 260 265 3770
Shovel ram, rod side 260 265 3770
Servo 27-35 27.5-35.6 391.5-508
Brake (non-adjustable) 80 81.6 1160
Steer relief pressure (at ram) 175 178.5 3262
Steer relief pressure (at pump) 190 193.8 2755
Pilot control pressure 27-33 27.5-33.6 391.5-478.6

Engine Cooling Fan rev/min

Fan Speed (tested @ engine speed of 2200 rev/min) 1600

By-pass Pressures bar kgf/cm 2 lbf/in2

Filter 1.5 1.53 22
Oil Cooler 3.0 3.06 44

Capacities Litres UKgal US gal

Hydraulic tank 181 39.8 47.9

Rams Bore Rod Dia. Stroke

mm in mm in mm in
Shovel Ram (HT 426) 100 3.9 60 2.4 1056 41.6
Shovel Ram (HT 436) 110 4.3 65 2.6 1056 41.6
Shovel Ram (ZX 426) 130 5.1 70 2.8 575 22.6
Shovel Ram (ZX 436, 446) 160 6.3 80 3.1 530 20.9

Lift Ram (426) 130 5.1 70 2.8 814 32.0

Lift Ram (436) 130 5.1 70 2.8 814 32.0
Lift Ram (446) 140 6.3 75 3.1 744 29.3

Steer Ram 80 3.1 50 2.0 312 12.3

Filter
Filtration Size 10 Micron
By pass Setting 1.5 bar

E-8 9803/4160-12 E-8

 Section E - Hydraulics
Technical Data
426 from Serial Number 532500, 436 from Serial Number 534200

Filter
Suction Strainer Size 140 Micron

E-9 9803/4160-12 E-9

 Section E - Hydraulics
Technical Data
426 from Serial Number 532847, 436 from Serial Number 534469

426 from Serial Number 532847, 436 from Serial Number 534469

Pump

Type Rexroth. Tandem variable displacement axial piston

Ref A20VO60 DFR1/10R-NSD24K01-S1296

Pump 1 litres/min UK gal/min US gal/min

Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (220 bar) 5 1.1 1.3

Pump 2
Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (160 bar) 5 1.1 1.3

Loader Valve

Type Rexroth, stacked directional control, model MP-22.

Services Operated
Section 1 (SV) Priority Steer
Section 2 (LV1) Loader arms
Section 3 (LV2) Shovel
Section 4 (LV3) Auxiliary (Quickhitch)
Section 5 (LV4) Auxiliary (Clam) (optional)

Relief Valve Operating Pressures bar kgf/cm 2 lbf/in2

Pump 1
Standby pressure (pump compensator valve) 27 27.5 391.5
System control pressure (pump relief valve) 245 - 255 250 - 260 3552 - 3697
Pump 2
Standby pressure (pump compensator valve) 25 25.5 362.5
System control pressure (pump relief valve) 155 - 165 158 - 168 2247 - 2394
Idle control pressure 45 45.9 652.7

E - 10 9803/4160-12 E - 10
 Section E - Hydraulics
Technical Data
426 from Serial Number 532847, 436 from Serial Number 534469

Auxiliary Relief Valves (A.R.V.)

Operating Pressures bar kgf/cm 2 lbf/in2

Lift ram, head side 345 352 4985
HT Shovel ram, head side 125 127 1812
ZX Shovel ram, head side 260 265 3770
Shovel ram, rod side 260 265 3770
Servo 27-35 27.5-35.6 391.5-508
Brake (non-adjustable) 80 81.6 1160
Steer relief pressure (at ram) 175 178.5 3262
Steer relief pressure (at pump) 190 193.8 2755
Pilot control pressure 27-33 27.5-33.6 391.5-478.6

Engine Cooling Fan rev/min

Fan Speed (tested @ engine speed of 2200 rev/min) 1600

By-pass Pressures bar kgf/cm 2 lbf/in2

Filter 1.5 1.53 22
Oil Cooler 3.0 3.06 44

Capacities Litres UKgal US gal

Hydraulic tank 181 39.8 47.9

Emergency Steer
Operating Pressure 40 bar

Rams Bore Rod Dia. Stroke

mm in mm in mm in
Shovel Ram (HT 426) 100 3.9 60 2.4 1056 41.6
Shovel Ram (HT 436) 110 4.3 65 2.6 1056 41.6
Shovel Ram (ZX 426) 130 5.1 70 2.8 575 22.6
Shovel Ram (ZX 436, 446) 160 6.3 80 3.1 530 20.9

Lift Ram (426) 130 5.1 70 2.8 814 32.0

Lift Ram (436) 130 5.1 70 2.8 814 32.0
Lift Ram (446) 140 6.3 75 3.1 744 29.3

Steer Ram 80 3.1 50 2.0 312 12.3

E - 11 9803/4160-12 E - 11
 Section E - Hydraulics
Technical Data
426 from Serial Number 532847, 436 from Serial Number 534469

Filter
Filtration Size 10 Micron
By pass Setting 1.5 bar
Suction Strainer Size 140 Micron

Accumulators

Gas Type
- Nitrogen

Gas Pre-Charge Pressures @ 20° C Bar PSI

Accumulator Function
- Brakes 57 826
- Automatic Carry Control System 16 232

Gas Volume (each) Litre Cubic inch

Accumulator Function
Brakes 0.75 45.8
Automatic Carry Control System 0.75 45.8

E - 12 9803/4160-12 E - 12
 Section E - Hydraulics
Technical Data
426 from M1231500, 436 from M1305000

426 from M1231500, 436 from M1305000

Pump

Type Rexroth. Tandem variable displacement axial piston

Ref A20VO60

Pump 1 litres/min UK gal/min US gal/min

Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (220 bar) 5 1.1 1.3

Pump 2
Standby flow 5 1.1 1.3
Full flow at 2200 rev/min 132 29.0 34.8
Flow at max. pressure (160 bar) 5 1.1 1.3

Engine Driven Charge Pump

Type Parker. Single, Fixed Displacement with Charge Valve
Ref tba
Displacement 20 cc/rev
Direction of Rotation Clockwise

Engine Driven Charge Pump litres/min UK gal/min US gal/min

Full flow at 2200 rev/min 42 9.24 11.1

Loader Valve

Type Rexroth, stacked directional control, model MP-22.

Closed centre, load sensing parallel circuit
Services Operated
Section 1 (SV) Priority Steer
Section 2 (LV1) Loader arms
Section 3 (LV2) Shovel
Section 4 (LV3) Auxiliary (Quickhitch)
Section 5 (LV4) Auxiliary (Clam) (optional)

E - 13 9803/4160-12 E - 13
 Section E - Hydraulics
Technical Data
426 from M1231500, 436 from M1305000

Relief Valve Operating Pressures bar kgf/cm 2 lbf/in2

Pump 1
Standby pressure 27 +3 -0 27.5 +3.06 -0 391.5 +43.5 -0
System control pressure 245 - 255 250 - 260 3552 - 3697
Pump 2
Standby pressure 25 +3 -0 25.5 +3.06 -0 362.5 +43.5 -0
System control pressure 155 - 165 158 - 168 2247 - 2394

Charge Valve Settings (Engine Driven Gear bar kgf/cm 2 lbf/in2

Pump)
Cut In Pressure 160 163.2 2320
Cut Out Pressure 200 204 2900
Max Pressure @ Port EF 220 224.4 3190

litres/min UK gal/min US gal/min

Total Flow to Accumulators 5 1.1 1.32

Auxiliary Relief Valve (ARV) Settings

Operating Pressures bar kgf/cm 2 lbf/in2

Inlet section Clipper relief valve 272 277.4 3944
Lift ram, head side 345 352 4985
HT Shovel ram, head side 125 127 1812
ZX Shovel ram, head side 260 265 3770
Shovel ram, rod side 260 265.2 3770
Servo 27-35 27.5-35.6 391.5-508
Brake (non-adjustable) 80 81.6 1160
Steer relief pressure (at ram) 175 178.5 3262
Steer relief pressure (at pump) 190 193.8 2755
Pilot control pressure 27-33 27.5-33.6 391.5-478.6

Engine Cooling Fan rev/min

Fan Speed (tested @ engine speed of 2200 rev/min)
426 Machines 1500
436 Machines 1600

By-pass Pressures bar kgf/cm 2 lbf/in2

Filter 1.5 1.53 22

E - 14 9803/4160-12 E - 14
 Section E - Hydraulics
Technical Data
426 from M1231500, 436 from M1305000

Capacities Litres UKgal US gal

Hydraulic tank 181 39.8 47.9

Emergency Steer
Operating Pressure 40 bar

Rams Bore Rod Dia. Stroke

mm in mm in mm in
Shovel Ram (HT 426) 100 3.9 60 2.4 1056 41.6
Shovel Ram (HT 436) 110 4.3 65 2.6 1056 41.6
Shovel Ram (ZX 426) 130 5.1 70 2.8 575 22.6
Shovel Ram (ZX 436, 446) 160 6.3 80 3.1 530 20.9

Lift Ram (426) 130 5.1 70 2.8 814 32.0

Lift Ram (436) 130 5.1 70 2.8 814 32.0
Lift Ram (446) 140 6.3 75 3.1 744 29.3

Steer Ram 80 3.1 50 2.0 312 12.3

Filter
Filtration Size 10 Micron
By pass Setting 1.5 bar
Suction Strainer Size 140 Micron

Accumulators

Gas Type
- Nitrogen

Gas Pre-Charge Pressures @ 20° C Bar PSI

Accumulator Function
- Brakes 57 +/- 1 825 + 30 - 15
- Automatic Carry Control System 24 +/- 1.0 bar 350 +/-15

Gas Volume (each) Litre Cubic inch

Accumulator Function
Brakes 0.75 45.8
Automatic Carry Control System 0.95 58

E - 15 9803/4160-12 E - 15
 Section E - Hydraulics

Basic Operation
General Description

426 service valve spool in the loader valve block to direct

pressurised oil from the pumps to the selected service ram.
The main components of the 426 Wheeled Loader Pressurised oil forces the piston along the bore to cause a
hydraulic system are the pump, priority valve, loader valve service movement. As the piston moves, oil is pushed from
block, servo control valve, steering valve, brake valve, the opposite end of the ram and returns to tank by way of
tank, rams and filters. For descriptions of the steering and a filter.
brake valves, refer to the relevant Sections.
Relief valves in the system prevent undue pressure rises
The pump is driven by the engine and delivers pressurised through internal and external sources.
oil to the system. A priority valve ensures that the steering
circuit has first demand on pump pressure. A pressure Valve Block Tie-Rods
regulated outlet from the end section of the loader valve is
routed to the servo control valve which in turn is redirected When assembling MP22 valve blocks, the tie-rods should
to the loader valve service spools as control inputs. be torque tightened to 55 - 60 lbf ft (74.6 - 81.4 Nm, 7.6 -
8.3 kgf m).
When the servo control valve is operated, it causes the
selected service valve spool in the loader valve block to
direct pressurised oil from the pump to the selected service
ram. Pressurised oil forces the piston along the bore to
cause a service movement. As the piston moves, oil is
pushed from the opposite end of the ram and returns to
tank by way of a filter.

Relief valves in the system prevent undue pressure rises

through internal and external sources.

436
The main components of the 436 Wheeled Loader
hydraulic system are the pumps, loader valve block,
priority valve, servo control valve, steering valve, brake
valve, tank, rams and filters. For descriptions of the
steering and brake valves, refer to the relevant Sections.

The primary pump (P1) and Secondary Pump (P2) are

driven by the engine to supply pressurised oil to the
system. P1 supplies the complete hydraulic system, P2
supplies the loader block spools only. When not required
to satisfy a demand from the loader circuits, pump P2
returns to standby mode. The priority valve ensures that
the steering circuit has first demand on pump pressure.

A pressure regulated output from the priority valve is

routed to the servo valve, which in turn is redirected to the
loader valve service spools as control inputs. When the
servo control valve is operated, it causes the selected

E - 16 9803/4160-12 E - 16
 Section E - Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols

Introduction to Hydraulic Schematic Symbols

TE-001

General (Basic and Functional Symbols) Table 2. Rams

Complex hydraulic components and circuits can be Single acting

described to the engineer by using graphical symbols. The
following pages illustrate and give a brief description for
some of the more common symbols used.
Double acting
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 Double ended
required you are recommended to obtain a copy of
BS2917 or IS01219.
Double acting with damping
Once familiar with the symbols, the engineer can use at rod area end
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. Table 3. Pumps and Motors

Table 1. General
Variable capacity pump two
Spring directions of flow

Flow restriction affected by

viscosity Fixed capacity motor one
direction of flow

Direction of flow

Fixed capacity motor two

directions of flow
Indication of rotation

Variable capacity motor one

Indication of direction and direction of flow
paths of flow

Variable capacity motor two

Variable control directions of flow

E - 17 9803/4160-12 E - 17
 Section E - Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols
Table 4. Control Valves

Used to enclose several Throttling orifice - normally

valves indicating they are closed
supplied as one unit

3-Position, 4-port spring Throttling orifice - normally

centered pilot operated valve open

3-position, 6-port spring

centered pilot operated valve

Relief valve
3-Position, 4-port spring
centered solenoid & pilot
pressure operated valve

3-Position, 4-port spring

centered detent hand Variable restrictor
operated valve

Non-return valve

Non-return valve with back

pressure spring

Pilot operated non-return

valve

One way restrictor

High pressure selector

(shuttle valve)

E - 18 9803/4160-12 E - 18
 Section E - Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols
Table 5. Energy Transmissions and Conditioning
Working line, return or feed Reservoir - return line below
fluid level
Pilot control

Drain lines

Header tank
Flexible pipe

Pressure sealed tank

Line junction

Accumulator

Crossing lines Filter or strainer

Water trap

Air bleed
Cooler - with no indication of
Line plugged, also pressure coolant flow
test point

Line plugged with take off line Cooler - indicating direction

of coolant flow

Quick release couplings -

connected
Heater
Quick release couplings -
disconnected

Reservoir - return line above

fluid level

E - 19 9803/4160-12 E - 19
 Section E - Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols
Table 6. Control Mechanisms
Solenoid one winding
Rotating shaft - one direction

Solenoid two windings

Rotating shaft - two directions

Detent Electric motor operated



Locking device Internal pressure pilot

operated

Over centre device

External pressure pilot
operated

Simple linkage
Pressure operated spring
release

General control
Pilot operated by solenoid
pilot valve

Push button operated

Pilot operated by a solenoid
or seperate pilot valve

Lever operated

Pressure guage

Pedal operated

Pressure switch
Stem operated

Spring operated

Roller operated

Roller trip operated (one

directional)

E - 20 9803/4160-12 E - 20
 Section E - Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols

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

Fig 1. ( E-21) shows a control valve represented by

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

Fig 4.

It must be noted that not all spools are of the same type.
Fig 1.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares.
Fig 2. ( E-21) - In circuit diagrams the pipework is
usually shown connected to the box which represents the
Three typical JCB style spools are known as 'D' spools, 'F'
unoperated condition. (Hydraulic circuit diagrams are
spools and 'N' spools.
usually shown in the unoperated condition).
The 'D' spools generally control rams because when in the
neutral position the outlet ports are blocked, preventing
ram movement. Fig 4. ( E-21) shows a 'D' type spool.

Fig 5. ( E-21) - 'F' spools are often shown as four

position spools with the three normal positions for neutral
and service control; and the forth position, which has a
Fig 2. detent, connects both sides of the ram together to allow the
service to 'float'.
Fig 4. ( E-21) shows a valve described as a 3-
position, 4-port control valve. Port describes the openings
to and from the valve by which the hydraulic fluid enters or
leaves. In the fig shown, Position 2 indicates that in an
unoperated condition all 4 ports are blocked.

Fig 5.

Fig 6. ( E-21) - 'N' spools are sometimes used to

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

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

the spool would connect Port P1 to Port P2, and Port P3 to
Port P4. Fig 4. ( E-21).

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

the spool would connect Port P1 to Port P4, and Port P3 to Fig 6.
Port P2. Fig 4. ( E-21).

E - 21 9803/4160-12 E - 21
 Section E - Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

Fig 7. Simple Schematic Circuit

Some of the symbols described on the preceding pages Example Circuit Key
have been arranged into a simple schematic circuit. Fig
7. ( E-22).
7-A Hydraulic Tank
Hydraulic tank 7-A is a pressurised tank with an internally 7-B Strainer
mounted strainer 7-B on the suction line to the fixed 7-C Fixed Displacement Pump
displacement pump 7-C. System pressure is limited to the
setting of relief valve 7-D. 7-D Relief Valve
7-E Spool
Valve spool 7-E is an open-centre spool that is in neutral 7-F One Way Valve
position; flow from the pump passes through the spool and
returns to the hydraulic tank. 7-G Double Acting Hydraulic Ram

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 7-G. Notice that the fluid must first
open one way valve 7-F before flowing to the ram.

E - 22 9803/4160-12 E - 22
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 23 9803/4160-12 E - 23
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 24 9803/4160-12 E - 24
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 25 9803/4160-12 E - 25
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 26 9803/4160-12 E - 26
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 27 9803/4160-12 E - 27
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 28 9803/4160-12 E - 28
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 29 9803/4160-12 E - 29
 Section E - Hydraulics
Circuit Diagrams
426 to M531203, 436 to M533195

E - 30 9803/4160-12 E - 30
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

426 with 4 Ram Loader

E - 31 9803/4160-12 E - 31
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 32 9803/4160-12 E - 32
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 33 9803/4160-12 E - 33
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 34 9803/4160-12 E - 34
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 35 9803/4160-12 E - 35
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 36 9803/4160-12 E - 36
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 37 9803/4160-12 E - 37
 Section E - Hydraulics
Circuit Diagrams
426 from M531204, 436 from M533196

E - 38 9803/4160-12 E - 38
 Section E - Hydraulics
Circuit Diagrams
Smoothshift Machines (426 from M532100, 436 from M533692)
426 from M532100, 436 from M533692)

426, 436 with 4 Bar Loader

E - 39 9803/4160-12 E - 39
 Section E - Hydraulics
Circuit Diagrams
Smoothshift Machines (426 from M532100, 436 from M533692)

E - 40 9803/4160-12 E - 40
 Section E - Hydraulics
Circuit Diagrams
Smoothshift Machines (426 from M532100, 436 from M533692)

E - 41 9803/4160-12 E - 41
 Section E - Hydraulics
Circuit Diagrams
Smoothshift Machines (426 from M532100, 436 from M533692)

E - 42 9803/4160-12 E - 42
 Section E - Hydraulics
Circuit Diagrams
436 from M534200 (Tier II)

E - 43 9803/4160-12 E - 43
 Section E - Hydraulics
Circuit Diagrams
436 from M534200 (Tier II)

E - 44 9803/4160-12 E - 44
 Section E - Hydraulics
Circuit Diagrams
436 from M534200 (Tier II)

E - 45 9803/4160-12 E - 45
 Section E - Hydraulics
Circuit Diagrams
436 from M534200 (Tier II)

E - 46 9803/4160-12 E - 46
 Section E - Hydraulics
Circuit Diagrams
426 from M532847

E - 47 9803/4160-12 E - 47
 Section E - Hydraulics
Circuit Diagrams
426 from M532847

E - 48 9803/4160-12 E - 48
 Section E - Hydraulics
Circuit Diagrams
426 from M532847

E - 49 9803/4160-12 E - 49
 Section E - Hydraulics
Circuit Diagrams
426 from M532847

E - 50 9803/4160-12 E - 50
 Section E - Hydraulics
Circuit Diagrams
436 from M534469

E - 51 9803/4160-12 E - 51
 Section E - Hydraulics
Circuit Diagrams
436 from M534469

E - 52 9803/4160-12 E - 52
 Section E - Hydraulics
Circuit Diagrams
436 from M534469

E - 53 9803/4160-12 E - 53
 Section E - Hydraulics
Circuit Diagrams
436 from M534469

E - 54 9803/4160-12 E - 54
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

Schematic Diagrams

E - 55 9803/4160-12 E - 55
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 56 9803/4160-12 E - 56
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 57 9803/4160-12 E - 57
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 58 9803/4160-12 E - 58
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 59 9803/4160-12 E - 59
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 60 9803/4160-12 E - 60
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 61 9803/4160-12 E - 61
 Section E - Hydraulics
Circuit Diagrams
426 from M1231500, 436 from M1305000

E - 62 9803/4160-12 E - 62
 Section E - Hydraulics
Circuit Descriptions
Pump Operation

E - 63 9803/4160-12 E - 63
 Section E - Hydraulics
Circuit Descriptions
Pump Operation

E - 64 9803/4160-12 E - 64
 Section E - Hydraulics
Circuit Descriptions
Pump Pressure/Flow Regulator Valves

Minimum Flow/Maximum Pressure

Hydraulic Service Operated
Start Up

E - 65 9803/4160-12 E - 65
 Section E - Hydraulics
Circuit Descriptions
Pump Pressure/Flow Regulator Valves

E - 66 9803/4160-12 E - 66
 Section E - Hydraulics
Circuit Descriptions
Start Up Valve

E - 67 9803/4160-12 E - 67
 Section E - Hydraulics
Circuit Descriptions
Start Up Valve

E - 68 9803/4160-12 E - 68
 Section E - Hydraulics
Circuit Descriptions
Loader Valve

E - 69 9803/4160-12 E - 69
 Section E - Hydraulics
Circuit Descriptions
Loader Valve

E - 70 9803/4160-12 E - 70
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Arms Raise/Lower

E - 71 9803/4160-12 E - 71
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Arms Raise/Lower

E - 72 9803/4160-12 E - 72
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Float

E - 73 9803/4160-12 E - 73
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Float

E - 74 9803/4160-12 E - 74
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Tip (4-Ram Loader)

E - 75 9803/4160-12 E - 75
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Tip (4-Ram Loader)

E - 76 9803/4160-12 E - 76
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Crowd (4-Ram Loader)

E - 77 9803/4160-12 E - 77
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Crowd (4-Ram Loader)

E - 78 9803/4160-12 E - 78
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Tip (Z-bar Loader)

E - 79 9803/4160-12 E - 79
 Section E - Hydraulics
Circuit Descriptions
Loader Valve - Shovel Crowd (Z-bar Loader)

E - 80 9803/4160-12 E - 80
 Section E - Hydraulics
Circuit Descriptions
Compensator Spool - Operation 1

E - 81 9803/4160-12 E - 81
 Section E - Hydraulics
Circuit Descriptions
Compensator Spool - Operation 1

E - 82 9803/4160-12 E - 82
 Section E - Hydraulics
Circuit Descriptions
Compensator Spool - Operation 2

E - 83 9803/4160-12 E - 83
 Section E - Hydraulics
Circuit Descriptions
Compensator Spool - Operation 2

E - 84 9803/4160-12 E - 84
 Section E - Hydraulics
Circuit Descriptions
Auxiliary Services

E - 85 9803/4160-12 E - 85
 Section E - Hydraulics
Circuit Descriptions
Auxiliary Services

E - 86 9803/4160-12 E - 86
 Section E - Hydraulics
Circuit Descriptions
Servo Pressure Regulating Valve

Neutral Standby Pressure

Service Operating

E - 87 9803/4160-12 E - 87
 Section E - Hydraulics
Circuit Descriptions
Servo Pressure Regulating Valve

E - 88 9803/4160-12 E - 88
 Section E - Hydraulics
Circuit Descriptions
Automatic Carry Control System (ACCS)

Automatic Carry Control System (ACCS)

Introduction use hydraulic pressure on one side of a diaphragm,

working against nitrogen gas pressure on the other, to
ACCS is a hydraulic suspension system that is designed to damp out the forces felt in the loader arms, so keeping the
enable a “cushion” effect for the loader lift rams, giving the machine steady at all times. The stabilisation valve is
benefit of a smoother ride when travelling over undulating solenoid activated through a speed sensing switch, and
terrain. The system is fully effective under all load operates automatically at speeds in excess of 7 km/hr. A
conditions, from full payload to empty shovel. manual override allows the system to be switched off if not
required and because the accumulators retain their charge
Nitrogen accumulators act via a stabilisation module valve at all times, there is no possibility of loader arm hydraulic
to balance the oil displacement across the lift rams as the collapse when the system is reactivated.
machine travels across rough terrain. The accumulators

Fig 46.

E - 89 9803/4160-12 E - 89
 Section E - Hydraulics
Circuit Descriptions
Automatic Carry Control System (ACCS)

Hydraulic Circuit

Component Key
A Stabilisation Module 6 2 Way Cartridge Valve
1 Solenoid Valve 7 Pressure Relief Valve
2 Accumulator 8 Loader Control Valve
3 Sequencing Valve 9 Lift Rams
4 Shut off Valve 10 Tank
5 2 Way Cartridge Valve

Fig 47.

E - 90 9803/4160-12 E - 90
 Section E - Hydraulics
Circuit Descriptions
Automatic Carry Control System (ACCS)

Operation
When driving at speeds in excess of 7 km/hr the solenoid
471 inside the stabilisation module 47A is switched on.
This connects the head side of the lift rams 47-9 to the
hydraulic accumulators 47-2.

During the working process, the solenoid 47-1 is switched

off so that the accumulators can be loaded up to a
maximum value of the set pressure during the lifting
operation. If the pressure on the head side of the lifting
rams is lower than the peak pressure in the accumulator,
the 2 way cartridge valve 47-5 closes. The accumulators
are not subjected to continuous pressure fluctuations.

The sequencing valve 47-3 and the pressure relief valve

47-7 in the stabilisation module limit the maximum
accumulator pressure. As the pressure in the accumulator
is always equal to or greater than the pressure in the lifting
rams, the bucket will be slightly raised when the
stabilisation system cuts in. Fig 48.

The piston side of the lifting rams is connected via a

second 2 way cartridge valve 47-6 to the tank. When the !MWARNING
system is activated both cartridge valves 47-5 and 47-6 The loader arms will fall to the ground if they are not
are operated simultaneously via the solenoid valve 47-1 on the ground or securely supported before the
this ensures cavitation free oscillation of the lifting ram isolating ball valve is opened. Ensure isolating ball
pistons. valve is open before attempting any maintenance work
on the load suspension hydraulic circuit. The isolating
Maintenance Safety ball valve is closed for normal system operation.
0106
Before attempting any maintenance work on the load
suspension hydraulic system, the isolating ball valve must
be OPEN.

The isolating ball valve is normally CLOSED for ACCS to

be operative.

E - 91 9803/4160-12 E - 91
 Section E - Hydraulics
Circuit Descriptions
ACCS 426 from M1231500, 436 from M1305000

Circuit Descriptions
General

E - 92 9803/4160-12 E - 92
 Section E - Hydraulics
Circuit Descriptions
ACCS 426 from M1231500, 436 from M1305000

E - 93 9803/4160-12 E - 93
 Section E - Hydraulics
Circuit Descriptions
ACCS 426 from M1231500, 436 from M1305000

E - 94 9803/4160-12 E - 94
 Section E - Hydraulics
Circuit Descriptions
ACCS 426 from M1231500, 436 from M1305000

E - 95 9803/4160-12 E - 95
 Section E - Hydraulics
Circuit Descriptions
ACCS 426 from M1231500, 436 from M1305000

WARNING

E - 96 9803/4160-12 E - 96
 Section E - Hydraulics
Circuit Descriptions
ACCS 426 from M1231500, 436 from M1305000

WARNING
Maintenance Safety

E - 97 9803/4160-12 E - 97
 Section E - Hydraulics
Circuit Descriptions
Electronic Emergency Steering

Electronic Emergency Steering

General
The emergency steering on 426 machines from serial
number 532847 and 436 machines from serial number
534469, has changed from a ground driven pump powered
from the machine’s transmission to an electronically driven
pump controlled by the EMS system.

The EMS system monitors the main hydraulic system

pressure. If the pressure falls below a preset limit the
emergency steering system will be activated automatically.

The system self tests every time the ignition is turned on

and will disable the machines starting system if a fault is
detected.

A switch is provided in the cab for the manual testing of the

system.

The pump and motor are located mounted to the front bulk-
head beneath the engine cover.

The system basically consists of a cab switch, low

pressure switch, pump 55A, motor 55B, in-line 100 Amp
fusible link 55C, solenoid 55D, system at pressure switch
55E and pressure adjusting screw 55F.

Fig 55.

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 Section E - Hydraulics

Fault Finding
Hydraulic Fault Finding

To use this section, look for the fault in the list below and Remember safety must always be the first priority, refer to
refer to the probable causes and actions required listed Section 2 - Care and safety for a reminder on safety
against the fault. practices.

Fault Possible Cause Action

1 Lack of power in all hydraulic Insufficient hydraulic fluid. Check for leaks and top up as required.
functions.
Hydraulic leaks in system. Check hoses, replace as required.
Engine performance. Check engine performance.
Pump control setting incorrect. Check and adjust as required.
Low pump flow. Check for external leaks, replace seals.
Priority valve sticking. Check priority valve.
2 All hydraulic rams slow to operate. Neutral circuit or low pressure lines Check pipe lines and replace as
leaking, damaged, trapped or kinked. required.
Pump control setting incorrect. Check and adjust as required.
Low pump flow Check pump flow.
Check for external leaks, replace seals.
Check for priority valve sticking.
3 One hydraulic service fails to Associated service pipe lines leaking, Check hoses, replace as required.
operate or is slow to operate. damaged, trapped or kinked.
Associated ram leaking. Replace seals.
A.R.V. setting incorrect. Check and adjust as required.
Associated valve block section leaking Check for leaks, rectify as required.
or not operating.
Check that the control lever is operating
the spool, rectify as required.
Associated check valve not opening to Check and rectify as required.
allow return of oil to tank.
Diverter not opening. Check electrical power supply and
valve operation, rectify as required.
4 The engine tends to stall when Pump control setting incorrect. Check and adjust as required.
hydraulics are under load.
Engine performance. Check engine performance.
5 Ram creep. Ram seals. Check and rectify as required.
A.R.V.

E - 99 9803/4160-12 E - 99
 Section E - Hydraulics

Service Procedures
Hydraulic Contamination
TE-002_2

Hydraulic Fluid Quality cleaning unit. Fig 56. ( E-100). General Bulletin 011
also refers.
Construction machinery uses a large volume of fluid in the
hydraulic system for power transmission, equipment Procedure
lubrication, rust prevention and sealing. According to a
survey conducted by a pump manufacturer, seventy per Connect the cleaning unit in place of the hydraulic filter.
cent of the causes of problems in hydraulic equipment Fig 56. ( E-100). Run the system for sufficient time to
were attributable to inadequate maintenance of the quality pump all the hydraulic fluid through the unit. Disconnect
of the hydraulic fluid. Therefore, it is obvious that control of the cleaning unit and reconnect the filter. Top up the
the quality of the hydraulic fluid helps prevent hydraulic system with clean hydraulic fluid as required.
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.

Effects of Contamination
Once inside the system, hydraulic circuit contaminants
greatly effect the performance and life of hydraulic
equipment. For example, contaminants in a hydraulic
pump develop internal wear to cause internal leakage and
hence lower discharges. Wear particles generated will
circulate with the hydraulic fluid to cause further
deterioration in the performance of this and other
equipment. Contaminants also enter principal sliding
sections of the equipment causing temporary malfunction,
scuffing, sticking and leakage and can lead to major
problems.The main contaminants can be classified as
follows:

1 Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear particles
etc.
Fig 56. Cleaning Unit
2 Liquid - usually water and incompatible oils and
greases.

3 Gases - Air, sulphur dioxide etc. which can create

corrosive compounds if dissolved in the fluid.

These contaminants can appear during manufacture,

assembly and operation.

Cleaning Operation
The purpose of cleaning oil is to remove contaminants of
all types and sludge by filtering hydraulic fluid through a

E - 100 9803/4160-12 E - 100

 Section E - Hydraulics
Service Procedures
Hydraulic Contamination

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:

– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)

– Human Hair = 70 microns (0.07 mm, 0.00275 in)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)

Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.

Standards will often be quoted to ISO (International

Standards Organisation) for which literature can be
obtained.

Filters
The filter assembly fitted to all product ranges is designed
to filter all the contamination that is generated through use
to the required level of cleanliness. The filter must be
serviced to the requirements of the machine Service
Schedules.

To ensure optimum performance and reliability it is

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

E - 101 9803/4160-12 E - 101

 Section E - Hydraulics
Service Procedures
Venting the Hydraulic Pressure

Venting the Hydraulic Pressure

426 from M1231500, 436 from M1305000 6 Turn OFF the ignition and disconnect the batteries to
ensure the machine cannot be started while the
hydraulic system is open.
!MWARNING
Hydraulic Pressure Automatic Carry Control System Venting
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses, Before attempting any maintenance work on the load
stop the engine and carry out the full venting suspension hydraulic system, the isolating ball valve must
procedure. Make sure the engine cannot be started be OPEN.
while the hoses are open.
INT-3-1-18 The isolating ball valve is normally CLOSED for ACCS to
be operative.
Machines from the serial number given above are fitted
with a new generation loader control valve. A feature of this
new valve is that when the ignition is turned off, the servo
control is disconnected from its pressure accumulator. This
can falsely give the impression should the control lever be
operated, that there is no residual pressure in the system.
To prevent the hydraulic system being opened whilst there
is still residual pressure present, the following venting
procedure MUST be carried out:

1 Park the machine on firm level ground. Lower the

attachments to the ground, apply the park brake and
set the transmission to neutral.

2 Switch the engine OFF.

3 Turn the ignition ON, but DO NOT start the engine.

4 Ensured the loader isolation switch in the right hand

side cab switch bank is turned ON. (The switch will be
illuminated when ON.) Fig 57. ( E-102)
Fig 58.

!MWARNING
The loader arms will fall to the ground if they are not
on the ground or securely supported before the
isolating ball valve is opened. Ensure isolating ball
valve is open before attempting any maintenance work
on the load suspension hydraulic circuit. The isolating
ball valve is closed for normal system operation.
Fig 57.
0106

5 Operate the loader control lever repeatedly to vent

any residual pressure.

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 Section E - Hydraulics
Service Procedures
Connecting and Disconnecting Hydraulic Hoses

Connecting and Disconnecting Hydraulic Hoses

The following paragraphs describe how to connect and 2 Disconnect the hoses. Where the connection is of the
disconnect hydraulic hoses safely. quick release type, see Section A, contents. For all
other hose connections, plug both sides of the
Connecting the Hoses connection to prevent loss of fluid.

1 Connect the hoses. Where the connection is of the

quick release type, see section A, contents. For all
other hose connections, use correct tools and ensure
that connections are not cross-threaded. Support the
weight of the hose until the connection is made. Do
not exceed the recommended torque loading.

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2

2 Check for leaks as follows:

a Start the engine.

b Operate the controls to pressurise the required

hose.

c Switch off the engine. Remove the starter key.

Check for signs of leakage at the hose
connections.

Disconnecting the Hoses

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5

1 Vent the hydraulic pressure as described Venting

the Hydraulic Pressure ( E-102).

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 Section E - Hydraulics
Service Procedures
`Positional Type' Hydraulic Adaptors

`Positional Type' Hydraulic Adaptors

Fitting Procedure
On a typical machine, some hydraulic components may
utilise `Positional Type' SAE Hydraulic Adaptors. When
fitting `Positional Type' Hydraulic Adaptors it is important to
adopt the following procedure. If this procedure is not
followed correctly, damage to the `O' ring seal 59A can
occur resulting in oil leaks.

1 Ensure the locknut 59B is screwed back onto the

body of the adaptor as far as possible as shown. 
2 Check the `O' ring backing washer 59C is a tight fit on
the adaptor. Note that the washer should not move
freely, if the washer is slack do not use the adaptor.  
3 Check the `O' ring 59A is fitted and that it is free from

damage or nicks. Before fitting the adaptor, smear the
`O' ring with clean hydraulic fluid. Fig 59.

Note: The dimensions and shore hardness of the `O' ring

is critical. Should it become necessary to replace the `O'
ring, ensure that only JCB Genuine Parts are used.

4 Screw the adaptor into the port of the hydraulic

component as far as possible, so that ALL the threads
engage and the `O' ring is correctly seated against
the sealing face.

5 Set the angular position of the adaptor as required,

then secure by tightening the locknut 59B.

Note: When fitted correctly no more than one thread

should be visible at 60Z as shown.

6 Torque tighten the locknut to 81 Nm (60 lbf ft).



Fig 60.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Flow and Pressure Tests

Main Pump - 426 Machines and check that the standby pressure is as stated in
Loader Valve ( E-1). If necessary, adjust at 63C.

!MWARNING Note: System control pressure will only show with the
Never walk or work under raised equipment unless it ESOS disconnected. When the ESOS is reconnected, the
is supported by a mechanical device. Equipment pressure shown will be approximately 50 bar.
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
13-2-3-7

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

If the articulation lock is not fitted you could be

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

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5
Fig 61.
Standby Pressure
System Control Pressure
1 Connect Pressure Test Gauge Kit 892/00253 (see
1 If you are using individual gauges, rather than Gauge
Note) to test point 62A on the emergency steer valve
Kit 892/00253, remove the existing gauge from test
assembly.
point 62A and connect a higher pressure gauge (see
Note).
!MCAUTION
2 Ensure that the engine rotation has stopped.
After checking the standby pressure, turn the starter
Reconnect the ESOS connector 61B.
key to HS to allow the engine rotation to stop. Do not
turn the key to OFF while the engine is turning;
3 Run the engine at idle and select ‘arms lower’ with
otherwise the test gauge may be damaged.
the shovel on the ground. Do not select ‘Float’
HYD-3-3

4 This will cause the hydraulic pressure to rise to the

2 Remove the ESOS connector 61B from the fuel
idle control pressure setting, which should be as
injection pump, crank the engine with the starter key

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests
stated in Loader Valve ( E-1). If necessary,
adjust the pressure at E

If the pressure is correct, Slowly increase engine speed to

Maximum. Pressure should rise to system control pressure
stated in Loader Valve ( E-1).

Note the engine speed at which the gauge indicates the

pressure rise and check against the figures in
Technical Data ( E-1). For adjusting engine speed,
see Idle Control Setting ( E-118).

If necessary adjust pressure at 63D.

Note: If Pressure Test Gauge Kit 892/00253 is not

available, use a suitable gauge which incorporates
protection against over pressurisation. See Technical
Data ( E-1) for pressures.

Fig 62.

Fig 63.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Main Pump - 436, 446 Machines Note: If Pressure Test Gauge Kit 892/00253 is not
available, use a suitable gauge which incorporates
protection against over pressurisation. See Technical
!MWARNING Data ( E-1) for pressures.
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if Secondary Pump Standby Pressure
the control is operated (even with the engine stopped).
13-2-3-7 1 Connect a Pressure Test Gauge Kit 892/00253 to test
point 64C on the secondary pump adaptor flange 2
(see Note 1).
!MDANGER
Make sure the articulation safety lock is fitted before 2 Run the engine at idle and check the pressure, which
transporting the machine. The articulation safety lock should be as stated in Technical Data ( E-1). If
must also be fitted if you are carrying out daily checks necessary, adjust at 64D.
or doing any maintenance work in the articulation
danger zone. 3 Stop the engine. Remove the pressure gauge from
test point 64C.
If the articulation lock is not fitted you could be
crushed between the two parts of the chassis. Main Pump System Pressure
GEN-3-1_1
1 Disconnect the 0 - 40 bar pressure gauge from test
!MWARNING point 64E. In its place connect a 0 - 400 bar pressure
gauge. (If the Pressure Test Gauge Kit is being used,
Hydraulic Pressure this step is not necessary.)
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses 2 Ensure that engine rotation has stopped. Reconnect
or couplings, vent the pressure trapped in the hoses in the electrical connector to the fuel pump shut-off
accordance with the instructions given in this valve 65X.
publication.
HYD-1-5 3 Run the engine at maximum RPM and select ‘arms
lower’ with the shovel on the ground. Do not select
Main Pump Standby Pressure ‘Float’.

1 Disconnect the electrical connector from the fuel This will cause the hydraulic pressure to rise to its
pump shut-off valve 65X. system control setting, which should be as stated in
Technical Data ( E-1). If necessary, adjust the
pressure at 64G. Stop the engine.
!MCAUTION
After checking the standby pressure, turn the starter Secondary Pump System Pressure
key to HS to allow the engine rotation to stop. Do not
turn the key to OFF while the engine is turning; 1 Transfer the pressure gauge to test point 64C.
otherwise the test gauge may be damaged.
HYD-3-3 2 Repeat step 9 with engine at idle, the gauge should
read standby pressure, already set at step 2. Slowly
2 Connect a Pressure Test Gauge Kit to test point 64E increase engine speed, pressure should rise to
on emergency steer valve (see Note). system control pressure as stated in Technical
Data ( E-1). If necessary, adjust the pressure at
3 With the engine cranking, check the pressure, which
should be as stated in Technical Data ( E-1). If
necessary, adjust the pressure at 64F.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests
64H (use 17 mm open end spanner with 70° - 90°
crank).

Note the engine speed at which the gauge indicates

the pressure rise and check against the figures in
Technical Data ( E-1). For adjusting engine
speed, see Idle Control Setting.

3 Stop the engine, remove the pressure gauge.

Note: If Pressure Test Gauge Kit 892/00253 is not

available, use a suitable gauge which incorporates
protection against over pressurisation. See Technical
Data ( E-1) for pressures.

Fig 65. 436

Fig 64.

Fig 66. 446

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Checking the Servo Pressure 6 If the pressure is too low, add shims to plug 67S.

Note: Ensure that the pump pressure settings are correct 7 If the pressure is too high, remove shims from plug
before checking the servo pressure. 67S.

1 Connect Pressure Test Gauge kit 892/00253 to test 8 Replace the plug 67S.
point 67R. (See Note.)
9 Start the engine and repeat the test.
2 Stop the engine and operate any service to discharge
the accumulator. 10 Repeat the procedure, if necessary, until the correct
pressure is achieved.
3 Start the engine.
11 Leave the gauge fitted for 3 minutes to see if the
4 Pressurise the system by operating the loader circuit holds its pressure. If pressure loss occurs
service; the pressure gauge should record the servo check the seating of the non-return valve and the
pressure stated in Technical Data ( E-1). accumulator.

5 If the recorded pressure is not as stated in Note: If Pressure Test Gauge Kit 892/00253 is not
Technical Data ( E-1), note whether pressure is available, use a suitable gauge which incorporates
too high or too low, switch off the engine and remove protection against over pressurisation. See Technical
plug 67S. Data ( E-1) for pressures.

Fig 67.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Pressure Testing the Loader Valve 4 Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure test
gauge to port ‘G’ (gauge) of the test block.
A.R.V.’s Using a Hand Pump
5 Port ‘T’ (tank) can be left open when using a hydraulic
!MWARNING hand pump.
Never walk or work under raised equipment unless it 6 Raise the pressure at the valve inlet using the
is supported by a mechanical device. Equipment hydraulic hand pump, when the A.R.V. ‘cracks’ and oil
which is supported only by a hydraulic device can
escapes from the port marked ‘T’ the pressure gauge
drop and injure you if the hydraulic system fails or if
will indicate the A.R.V. setting.
the control is operated (even with the engine stopped).
13-2-3-7 7 If the A.R.V. setting is correct as stated in
Technical Data ( E-1), release the pressure in
To pressure test and re-set the loader auxiliary relief valves
the test block and remove the A.R.V. assembly. Refit
(A.R.V.), the following equipment must be used:
the A.R.V. in the loader valve block.

892/00340 Test Block Body 8 If the A.R.V. setting needs to be adjusted release
892/00223 Hand Pump locknut 69W and adjust 69V, using a 5 mm Allen Key
and repeat the test until the correct pressure is
892/00279 Pressure Gauge 0 - 400 bar obtained. Tighten the locking nut to preserve the
setting. If the specified pressure is higher than the
Other associated equipment as detailed in Section 1 - maximum achievable by adjustment, additional shims
Service Tools. will need to be fitted.

1 Remove the loader valve A.R.V.’s from the loader 9 When the correct A.R.V. setting has been attained,
valve block. Note their positions for correct release the pressure in the test block. Remove the
reassembly. A.R.V. assembly and refit it to its correct position in
the loader valve block.
2 Install the first A.R.V. assembly in the test block at the
port marked ‘RV’ (relief valve). 10 Repeat the procedure for the other A.R.V.’s.

Fig 68.

3 Connect a hydraulic hand pump to port ‘P’ (pump) of

the test block. Make sure that the hand pump is filled
with JCB Hydraulic Fluid.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Fig 69.

E - 111 9803/4160-12 E - 111

 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Tandem Pumps

!MWARNING
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
13-2-3-7
Fig 70.

!MDANGER 2 Remove the load sensing (LS) line 71B from the
Make sure the articulation safety lock is fitted before pump and plug the hose. Leave the pump connection
transporting the machine. The articulation safety lock open to atmosphere.
must also be fitted if you are carrying out daily checks
3 Start the engine and with the engine at low idle
or doing any maintenance work in the articulation
observe the gauge reading. Dependant on ambient
danger zone.
temperature this could be in the range 32 to 180 bar.
DO NOT ADJUST at this stage. Stop the engine.
If the articulation lock is not fitted you could be
crushed between the two parts of the chassis.
4 Fit a 40 bar pressure gauge in place of the 400 bar
GEN-3-1_1
gauge (providing the pressure recorded at Step 3 is
below 40 bar) and start the engine. Check the
!MWARNING standby pressure is as stated in Technical
Data ( E-1). If necessary adjust.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
5 To adjust the standby pressure, (71C for main pump,
Before disconnecting or connecting hydraulic hoses
71D for secondary pump) hold the lock nut 71E with
or couplings, vent the pressure trapped in the hoses in
a 17 mm spanner and remove the domed nut 71F.
accordance with the instructions given in this
Note: a sealing washer 71Y is fitted in a recess in the
publication.
domed nut, retain for later refitment. Insert a 3 mm
HYD-1-5
hexagon key into the threaded section 71G and
loosen the lock nut. Adjust as required. This
!MCAUTION adjustment is very sensitive. Tighten the lock nut,
replace the domed nut and secure. Check the
Due to ambient temperature variations worldwide it is
pressure has not altered. Stop the engine.
recommended that initial checks of "Standby"
pressure are taken using a 400 bar gauge.
6 Fit the 40 bar gauge to the secondary pump test point
HYD-1-6
70H.
Standby Pressure Note: There should be a difference of 2 bar between the
main pump and secondary pump standby pressures.
1 Connect a 400 bar gauge to the main pump test point
70A. 7 Start the engine and check the secondary pump
standby pressure. If required adjust as detailed in
step 5 above.

8 Refit the load sensing line to the pump.

9 Remove the 40 bar test gauge.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests
3 To adjust the maximum pressure, (73J for main
pump, 73K for secondary pump) hold the lock nut 73L
with a 17 mm spanner and remove the domed nut
73M. Note: a sealing washer 73Y is fitted in a recess
in the domed nut, retain for later refitment. Insert a 3
mm hexagon key into the threaded section 73N and
loosen the lock nut. Adjust as required. This
adjustment is very sensitive. Tighten the lock nut,
replace the domed nut and secure. Check the
pressure has not altered. Stop the engine.

4 Remove the 400 bar gauge from the main pump test
point and fit to the secondary pump test point 72H.

5 Start the engine, crowd the bucket, select arms down

and hold to read the maximum operating pressure for
the secondary pump. Check the maximum pressure
is as stated in Technical Data ( E-1). If
necessary adjust as detailed in step 3 above.

Fig 71.

Main Pressure

1 Fit a 400 bar gauge to the main pump test point 72A.
(Ensure the load sensing line has been reconnected
after checking the standby pressure.)

2 Start the engine, crowd the bucket, select arms down

and hold to read the maximum operating pressure for
the main pump. Check the maximum pressure is as
stated in Technical Data ( E-1). If necessary
adjust.

Fig 73.

Fig 72.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Servo Pressure - Tandem Pumps

!MWARNING
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
13-2-3-7
Fig 74.

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

If the articulation lock is not fitted you could be

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

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5

1 Operate the servo lever a minimum of 10 times to

vent the pressure from the servo system. Fit a 40 bar
test gauge to the servo test point 74A.

2 Start the engine. The pressure should rise to the

range detailed in Technical Data ( E-1).

No adjustment is normally required, however it is possible

to increase the pressure by fitting a shim beneath the cap
on the servo regulator slice. Do NOT do this unless the
Standby Pressure has already been verified as correct.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Steering Relief Valve

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

If the articulation lock is not fitted you could be

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

1 Connect Pressure Test Gauge Kit 892/00253 to test

point 75A (see Note).

2 Turn the steering wheel and check that the indicated

pressure is as stated in Technical Data ( E-1)
‘At Pump’ pressure.

3 If the indicated pressure does not meet the specified

pressure, do the following:

a Separate the hydraulic steering unit from the

steering column, leaving the hoses connected.

b Remove the steer relief valve (see Section H -

Steering). Dismantle, clean and refit the relief
valve. Reassemble the steer valve to the steer
column. Repeat steps 1 and 2. If the pressure is
still incorrect, the steering unit will need to be
renewed.

Note: If Pressure Test Gauge Kit 892/00253 is not

available, use a suitable gauge which incorporates
protection against over pressurisation. See Technical
Data ( E-1) for pressures.

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Two-Stage Shovel Ram (Head Side) required, release locknut 76M and rotate 76P until the
gauge shows the appropriate reading.

!MDANGER 5 Tighten locknut 76M ensuring that the pressure stays

Make sure the articulation safety lock is fitted before at the value set at step 4.
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks To set 2nd stage pressure
or doing any maintenance work in the articulation
danger zone. 1 Unplug and reconnect hose to connector 76L.

If the articulation lock is not fitted you could be 2 Operate the shovel tip with the loader arms as close
crushed between the two parts of the chassis. to the ground as possible.
GEN-3-1_1
3 Release locknut 76N and rotate 76P until the
To Set First Stage Pressure pressure registered on the pressure gauge is the
same as that specified in Technical Data ( E-1).
1 Connect Pressure Test Gauge Kit 892/00253 to test
point 75A (see Note). Note: As the pressure increases beyond 150 bar, the
engine may labour. Counteract this by increasing the
engine revs.

4 Once the reading is stable tighten the locknut 76N

ensuring that the pressure remains as set at step 3
with no load on the engine.

Rechecking 1st stage setting

To ensure that the 2nd stage adjustment procedure has not

affected the 1st stage setting, remove the connector from
76L and plug to prevent oil loss.

1 Run the engine at idle speed and operate the shovel

tip with the loader arms as close to the ground as
possible.

2 If an adjustment is necessary, release locknut 76M

and rotate 76P until the pressure gauge reads the
correct value. After satisfactory adjustment tighten
Fig 75.
the locknut, refit the hose to 76L and remove the
pressure gauge.
Note: If Pressure Test Gauge Kit 892/00253 is not
available, use a suitable gauge which incorporates
Note: If pressure settings, as detailed in Technical Data,
protection against over pressurisation. See Technical
prove difficult to attain proceed as follows:
Data ( E-1) for pressures.
1 Remove connector from 76L.
2 Remove the hose from point 76L and prevent oil loss
by fitting plug 892/00055 to the hose.
2 Slacken locknut 76N.
3 Operate the shovel tip with the loader arms as close
3 Rotate 76P until the barrel runs free, retighten to the
to the ground as possible.
point where resistance is felt then undo half a turn.
4 Check that the pressure gauge reads the value stated
4 Repeat the pressure setting procedures.
in Technical Data ( E-1). If adjustment is

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 Section E - Hydraulics
Service Procedures
Flow and Pressure Tests

Fig 76.

E - 117 9803/4160-12 E - 117

 Section E - Hydraulics
Service Procedures
Idle Control Setting

Idle Control Setting

426, 436 Machines

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

If the articulation lock is not fitted you could be

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

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in Fig 77. 426
accordance with the instructions given in this
publication. 436 - test point 78C on the secondary pump adaptor
HYD-1-5 flange.

1 Connect Pressure Test Gauge Kit 892/00253 (see

Note) to:

426 - test point 77A on the emergency steer valve

assembly.

Fig 78. 436

2 Run the engine at idle and select ‘arms lower’ with

the shovel on the ground. Do not select ‘Float’.

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 Section E - Hydraulics
Service Procedures
Idle Control Setting
3 Slowly increase engine speed to Maximum. Pressure
should rise to system control pressure stated in
Technical Data ( E-1).

Note the engine speed at which the gauge indicates the

pressure rise.

The pressure reading should rise at the engine speeds

stated in Technical Data ( E-1).

Before adjusting the position of the proximity switch check

the gap 79X which should be 2 mm (0.08 in).

Fig 79.

If the pressure rises below the engine speed stated, move

the proximity switch forward in the slot. If the pressure rises
above the engine speed stated, move the proximity switch
back in the slot. Secure the proximity switch.

Repeat step 3 until engine speed is correct.

Note: If Pressure Test Gauge Kit 892/00253 is not

available, use a suitable gauge which incorporates
protection against over pressurisation. See Technical
Data ( E-1) for pressures.

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 Section E - Hydraulics
Service Procedures
Hydraulic Cooling Fan Setting

Hydraulic Cooling Fan Setting

436 Machines to M1305000 1 On the right hand side of the machine, slacken the
locknut 80A on the fan motor and adjust to achieve
the recommended speed.
!MDANGER
Make sure the articulation safety lock is fitted before If the fan exceeds the required speed, reduce the
transporting the machine. The articulation safety lock speed to at least 100 rpm below the requirement then
must also be fitted if you are carrying out daily checks increase slowly to obtain the correct speed.
or doing any maintenance work in the articulation
danger zone.

If the articulation lock is not fitted you could be

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

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5

!MWARNING
When working close to the machine with the engine
running, protective clothing must be worn, ie. Safety
glasses, ear protection, gloves etc.
Fig 80.
GEN-4-3

2 Tighten the locknut and recheck the fan speed.

Fan Drive Without Reversing Facility

1 Attach tacho-reflective tape to the fan hub (rather

than to the fan blades).

2 Warm up the hydraulic system until 4 or 5 segments

show on the hydraulic temperature gauge.

3 Hold the engine at Max specified revs. Check max

engine revs in Technical Data ( E-1).

4 Check fan reaches its recommended speed as

detailed in Technical Data ( E-1).

Adjusting the Fan Speed

Note: Screw the adjuster in to increase fan speed and

pressure, out to decrease.

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 Section E - Hydraulics
Service Procedures
Hydraulic Cooling Fan Setting
Fan Drive With Reversing Facility Note: it is normal for the reverse rotation fan rpm not to
match the forward rotation rpm
Note: Fan drive motors for machines fitted with a reverse
fan facility will have two adjusting screws on the motor Fan Speed Adjustment
body, one on each side.
Three adjusters on the reversing valve control the fan
1 Screw both adjusters 80A on the fan motor fully in speed.:
(clockwise) and tighten the locknuts.
1 Main Relief Valve R1 (largest adjuster) sets both
2 Fit 200 bar pressure gauge to the test point 81B on forward and reverse modes simultaneously
the engine driven fan drive pump to measure the fan
motor pressure. 2 R2 (port B) controls the forwards direction of
rotation.

3 R3 (port A) controls the reverse direction of rotation.

Note: Screw the adjuster in to increase fan speed and

pressure, out to decrease.

Fig 81.

3 Attach tacho-reflective tape to the fan hub (rather

than to the fan blades).

4 Warm up the hydraulic system until 4 or 5 segments

show on the hydraulic temperature gauge.

5 Hold the engine at Max specified revs. Check max

engine revs in Technical Data ( E-1). Fig 82.

6 Measure the fan speed and record. 4 To adjust both forward and reverse setting
simultaneously, slacken the locknut on the main relief
7 Measure the feed pressure to the fan for normal valve @ R1 82A and adjust at obtain the correct
direction of rotation and record. The maximum speed. (Record the speed and pressure setting for
recommended pressure is 160 bar. both directions.) (Maximum Pressure 160 bar.)

8 Set the fan to the reverse direction of rotation and 5 Tighten the locknut and recheck the fan speed.
measure the pressure (Max 160 bar). Record the
pressure obtained. If the fan exceeds the required speed, reduce the
speed to at least 100 rpm below the requirement then
increase slowly to obtain the correct speed.

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 Section E - Hydraulics
Service Procedures
Hydraulic Cooling Fan Setting
6 To adjust the forward rotation speed only, slacken the DLY>0). The fan will change direction immediately
locknut @ R2 82B and adjust at obtain the correct and run in reverse for the programmed duration.
speed. (Record the speed and pressure setting for
both directions.) (Maximum Pressure 160 bar.) 5 To disable the fan reversing function set the FAN R
DLY = 0 or unplug the wires to the reversing valve.
If the fan exceeds the required speed, reduce the
speed to at least 100 rpm below the requirement then
increase slowly to obtain the correct speed.

7 Tighten the locknut and recheck the fan speed.

8 To adjust the reverse rotation speed only, slacken the

locknut @ R3 82C and adjust at obtain the correct
speed. (Record the speed and pressure setting for
both directions.) (Maximum Pressure 160 bar.)

If the fan exceeds the required speed, reduce the

speed to at least 100 rpm below the requirement then
increase slowly to obtain the correct speed.

9 Tighten the locknut and recheck the fan speed.

Reversing Fan Software

Two files are required:

1 ***emslang.ini. Replace the existing file in the JCB2

directory on the laptop hard drive.

2 Instal FAN/00004.hex or latest version into EMS.

Programming the Reversing Fan

Frequency and Duration
Fan direction and duration can be programmed via the
EMS.

1 In “Prestart Mode” (i.e. mode where you can set the

time clock), press the SETUP key and scroll through
the Clock/Date settings until you reach FAN F DLY.
Set the fan forwards duration using the arrow keys.

2 Press the SETUP key again to display FAN R DLY.

Set the reverse duration using the arrow keys.

Recommended initial settings are: 3600 Forwards, 20

Reverse (time displayed in SECONDS)

3 Press the manual key to exit set-up.

4 Reverse direction can be manually selected at any

time by pressing the “Down Arrow” (providing FAN R

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 Section E - Hydraulics
Service Procedures
Hydraulic Cooling Fan Setting

426 Machines from M1231500, 436 adjustment. Screw the adjuster in to increase the fan
speed and pressure, out to decrease.
Machines from M1235000
1 Slacken the locknut A on the fan motor relief valve
!MDANGER cartridge using a 13 mm spanner and slow turn the
adjusting screw using a 4 mm Allen key to obtain the
Make sure the articulation safety lock is fitted before recommended speed.
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks If the fan exceeds the recommended speed, reduce
or doing any maintenance work in the articulation the speed by at least 100 rpm below the requirement
danger zone. then slowly increase until the correct speed is
obtained.
If the articulation lock is not fitted you could be
crushed between the two parts of the chassis.
GEN-3-1_1

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5

!MWARNING
When working close to the machine with the engine
running, protective clothing must be worn, ie. Safety
glasses, ear protection, gloves etc.
GEN-4-3

Checking the Fan Speed

1 Attach tacho-reflective tape to the fan hub rather than

to the fan blades. Fig 83. Uni-Directional Fan Motor

2 Warm up the hydraulic system until 4 or 5 segments

show on the hydraulic oil temperature gauge.

3 Hold the engine at Max specified revs as detailed in

Technical Data ( E-1).

4 Check the fan reaches its recommended speed as

detailed in Technical Data ( E-1).

Adjusting the Fan Speed

Fig 83. ( E-123) and Fig 84. ( E-124).

Note: Make adjustments to the adjusting screw in small

increments only. Recheck the fan speed after each

E - 123 9803/4160-12 E - 123

 Section E - Hydraulics
Service Procedures
Hydraulic Cooling Fan Setting

Fig 84. Bi-Directional Fan Motor

2 Tighten the locknut A and recheck the fan speed.

E - 124 9803/4160-12 E - 124

 Section E - Hydraulics
Service Procedures
Emergency Steering (Electronic)

Emergency Steering (Electronic)

Checking/Adjusting the System 4 Remove the 400 bar test gauge.

Pressure
Note: Electronically controlled emergency steering was
introduced on the 426, 436 models from the following
serial numbers: 426 - S/N 532847, 436 - S/N 534469.

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

If the articulation lock is not fitted you could be

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

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses Fig 85.
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this Adjusting the Pressure
publication.
HYD-1-5 Important: If the pressure needs to be adjusted, providing
the pressure is not greater than 50 bar, replace the 400 bar
Checking the pressure test gauge with a 50 bar one. The pressure setting is quite
critical and an analogue 400 bar gauge may not be
1 Connect a 400 bar test gauge to the test point 85T. sensitive enough to fine tune the output pressure. (A 400
bar calibrated “Digital” gauge may be used as an
Note: The emergency steering system test point (85T) is alternative.)
located beneath the front panel, on the right hand side of
the loader valve when viewed from the front of the Note: the adjuster is very sensitive, make only very small
machine. adjustments at the adjusting screw.

2 With the engine switched OFF, turn on the ignition. 1 Connect a 50 bar test gauge to the test point 85T, (the
Wait for the EMS System to carry out its self maximum pressure having already been confirmed
diagnostic test (approximately 4 seconds). Depress as being below 50 bar).
and hold the Emergency Steer Test Switch in the cab.
Read and record the pressure generated on the test 2 Turn on the ignition but do not start the engine.
gauge. Depress and hold the emergency steering test switch
and check the pressure.
3 Release the switch once the pressure reading has
been obtained. Check the pressure reading against 3 Release the switch (there is no need to run the pump
the system max pressure as detailed in Technical whilst adjusting).
Data ( E-1).

E - 125 9803/4160-12 E - 125

 Section E - Hydraulics
Service Procedures
Emergency Steering (Electronic)
4 Hold the nut 86H and release the locknut 86G. Using
an Allen key inserted into the threaded adjuster 86F,
adjust as required.

5 After each small alteration to the adjuster 86F, nip the

locknut 86G. With the ignition on, depress and hold
the emergency steer test switch and record the
reading.

6 Release the switch before making any adjustment to

the pressure.

7 Continue making small alterations to the adjuster until

the correct pressure as detailed in Technical
Data ( E-1) has been achieved.

8 Tighten the locknut and recheck the pressure.

9 Remove the test gauge.

Fig 86.

E - 126 9803/4160-12 E - 126

 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)

Automatic Carry Control System (ACCS)

Accumulators
Important: All hydraulic pressure must be removed from
the accumulator BEFORE any attempts to adjust the Gas
Charge Pressures are made. Refer to Venting the
Hydraulic Pressure ( E-102).
 
Identifying Piston Accumulators

There are two different types of piston accumulator that

may be fitted to your machine.

The earlier of the two, Type 1, can have the internal seals
replaced should the accumulator fail to hold its gas charge
due to worn or damaged seals.

The later Type 2 accumulators cannot be overhauled and,

should they prove unserviceable, will need to be replaced.

The Type 2 is a direct replacement for the Type 1 should a Fig 87.
type 1 prove to be unserviceable.

The two types can be easily identified by a visual

inspection of the gas end of the cylinder.

The Type 1 A has a brass charge valve cap and the

threaded end cap is quite visible.

The Type 2 B has a large steel nut covering the charge

valve and the ends of the cylinder are swaged with no
obviously removable end cap.

E - 127 9803/4160-12 E - 127

 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)
Charging the Accumulators 5 Carefully open the gas bottle valve 88C and watching
the gauge, allow nitrogen to flow until the pressure
The accumulators must be charged before fitting. Charge reading reaches 20 bar (290 lb/in2).
the accumulators as follows:
Close the gas bottle valve 88C.
Sphere Type
6 Adjust the pressure in the accumulator by carefully
opening and closing the discharge valve of the
!MWARNING charging device 88A to the value listed in
Use only nitrogen gas to charge accumulators. The Technical Data ( E-1).
use of any other gas can cause the accumulators to
explode. Remember that although nitrogen is not Via the charging device, shut filler plug 88B and
poisonous you can be killed by suffocation if it tighten to a torque of 20 Nm (15 lb ft).
displaces the air in your workplace. Do not allow
excessive quantities of nitrogen to be discharged into 7 Release the pressure from the gas bottle hose by
the atmosphere. opening the discharge valve of the charging device
B-3-1-6 88A.

8 Disconnect the charging device from the

!MDANGER accumulator.
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock 9 Check the gas-tightness of filler plug 88B by pouring
must also be fitted if you are carrying out daily checks soapy water around it.
or doing any maintenance work in the articulation
danger zone. 10 Replace plastic cap.

If the articulation lock is not fitted you could be

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

1 Remove plastic cap from the top of the accumulator.

2 Connect the nitrogen charging tool kit 88A (892/

01042 and 892/01043 (connector)) to the
accumulator. (Note charging tool kit 892/00239 as
used in the brake section can be used as an
alternative.)

3 Via the charging device, open the filler plug 88B by

three turns.

4 Open the discharge valve of the charging device.

Fig 88.
Carefully open the nitrogen gas bottle valve and
confirm that the nitrogen gas flows freely.

Shut the gas bottle valve 88C and the discharge valve
of the charging device.

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 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)
Piston Type 1 charging device D to the value listed in Technical
Data ( E-1).
!MWARNING 8 When complete, screw handle C all the way out
Use only nitrogen gas to charge accumulators. The (counter clockwise) and then open the discharge
use of any other gas can cause the accumulators to valve D to vent the hose.
explode. Remember that although nitrogen is not
poisonous you can be killed by suffocation if it 9 Hold the gas valve to prevent it from turning and
displaces the air in your workplace. Do not allow loosen nut G. Disconnect the charging device from
excessive quantities of nitrogen to be discharged into the accumulator.
the atmosphere.
B-3-1-6 10 Replace the brass valve cap and valve guard.

!MDANGER

Make sure the articulation safety lock is fitted before 
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation
danger zone. 
If the articulation lock is not fitted you could be
crushed between the two parts of the chassis.
GEN-3-1_1

 
1 Remove the gas valve guard A and gas valve cap B.

2 Screw handle C all the way out (counter clockwise)

before attaching the charging tool to the accumulator
gas valve.

3 Close the discharge valve D.

4 Make sure not to loop or twist the hose and connect

the nitrogen charging tool kit 892/00949 to the
accumulator.
Fig 89.
5 Connect the charging tool to a bottle of compressed
nitrogen gas fitted with a regulator valve, set to
minimum pressure.

6 Screw handle C all the way in (clockwise), this will

depress the core in the gas valve.

Carefully open the nitrogen gas bottle valve E and

watching the gauge, allow nitrogen to flow by
increasing the pressure regulator setting until the
pressure reading reaches 20 bar (290 lbf/in2) Close
the gas bottle valve E.

7 Adjust the pressure in the accumulator by carefully

opening and closing the discharge valve D of the

E - 129 9803/4160-12 E - 129

 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)
Piston Type 2 7 Adjust the pressure in the accumulator by carefully
opening and closing the discharge valve D of the
!MWARNING charging device to the value listed in
Data ( E-1).
Technical

Use only nitrogen gas to charge accumulators. The

use of any other gas can cause the accumulators to Via the charging device, shut filler plug C and tighten
explode. Remember that although nitrogen is not to a torque of 20 Nm (15 lb ft).
poisonous you can be killed by suffocation if it
displaces the air in your workplace. Do not allow 8 Release the pressure from the gas bottle hose by
excessive quantities of nitrogen to be discharged into opening the discharge valve D of the charging device.
the atmosphere.
B-3-1-6 9 Disconnect the charging device from the
accumulator.
!MDANGER 10 Check the gas-tightness of filler plug B by pouring
Make sure the articulation safety lock is fitted before soapy water around it.
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks 11 Replace the steel cap A.
or doing any maintenance work in the articulation
danger zone.

If the articulation lock is not fitted you could be 
crushed between the two parts of the chassis.
GEN-3-1_1

1 Remove the steel cap A from the charge valve B of

the accumulator.


2 Connect the nitrogen charging tool kit 892/01042 and

892/01043 to the accumulator. 
 
3 Making sure not to loop or twist the hose, connect the
charging tool to a bottle of compressed nitrogen gas
fitted with a regulator set to minimum pressure.

4 Via the charging device, open the charge valve plug

C by three turns.

5 Open the discharge valve D of the charging device.

Carefully open the nitrogen gas bottle valve and C031140

confirm that the nitrogen gas flows freely.
Fig 90.
Shut the gas bottle valveE and the discharge valve D
of the charging device.

6 Carefully open the gas bottle valve E and watching

the gauge, allow nitrogen to flow by increasing the
pressure regulator setting until the pressure reading
reaches 20 bar (290 lb/in2).

Close the gas bottle valve E.

E - 130 9803/4160-12 E - 130

 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)

Dismantling, Inspection and Assembly !MCAUTION

Piston (Type 1) Accumulators Only Do not remove the piston by applying compressed air
at the opposite end.
Note: The Sphere and Piston Type 2 accumulators are HYD-2-7
sealed for life. No attempt should be made to open an
accumulator of either of these types. If they are found not Inspection
to be holding their gas charge they should be replaced.
Inspect the piston for cracks, burrs around the O-ring
Note: Discarded accumulators must be disposed of in line grooves or damage. Examine the body bore 1, using a
with local regulations. light, for scratches or scoring. Inspect the end caps for
damaged threads or burrs on the O-ring grooves.

!MDANGER Minor nicks, scratches or light scoring of the body bore

Discharge all gas pressure before dismantling the may be removed by using a very fine abrasive paper.
accumulators. Failure to comply can cause rapid Dress the bore until all the apparent imperfections have
discharge of gas and/or hydraulic fluid which can been removed.
result in death, personal injury and damage to the
machine. All seals and O-rings must be discarded and new ones
0044
fitted.

Dismantling Assembly

Piston Accumulator (Type 1) 1 Coat all the internal components with clean hydraulic
Components ( E-133). fluid.

1 Check that the accumulator you are working on has 2 Fit the piston seal 9, teflon back up rings 10 and seals
been fully discharged. 11.

2 Secure the accumulator in a horizontal position. 3 Install the piston assembly into the bore 1 with the
hollow side of the piston facing towards the Gas-End
of the cylinder. Insert the piston squarely and slowly
!MCAUTION so as to avoid letting the piston seal to drag on the
The gas end cap (cap with gas valve) must be removed cylinder threads.
before the hydraulic end cap. This allows any residual
pressure to escape through the safety vent holes. If The piston is a tight fit inside the bore. Once the seals
the hydraulic end cap is removed first the piston will have become fully engaged in the honed bore, the
cover the safety vent holes which could result in the piston can be eased into the bore using a mallet and
piston being forced out under pressure. a suitable block of wood.
HYD-2-6
The piston should be inserted until the outer face of
3 Fit three pins into the holes in the gas end cap 4 and, the piston is a minimum of 2 inches (50 mm) below
using a long bar working against the pins unscrew the the point at which the honed bore of the cylinder
end cap. begins.

4 Remove and discard the O-rings and back up rings Note: Keep pressure applied to the piston while inserting
from the end cap. particularly if using a mallet to drive the piston, as the start
of the bore is chamfered, releasing the pressure may allow
5 Remove the piston 6 by pushing from the hydraulic the piston to ‘bounce’ which could damage the piston ring.
end with a bar.
4 Install the end cap seal 7, it is important that the seal
is installed with the leading edge A pointing in a

E - 131 9803/4160-12 E - 131

 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)
counter clockwise direction otherwise the seal may
bind when the end cap is fitted.

5 Install the end cap O-rings 8, it is important that the

seals 7 and 8 are fitted in the correct position in
relation to each other to prevent leaks.

6 Fit the end caps 4 and 5, use pins and a long bar.
Make sure the gas end cap is fitted to the correct end.
The piston hollow end to the gas cap.

Note: The end caps will stop against the chamfer leading
into the honed bore. O-ring sealing in not dependant upon
cap tightness.

7 Install a new O-ring 13 and install the gas valve 12.

E - 132 9803/4160-12 E - 132

 Section E - Hydraulics
Service Procedures
Automatic Carry Control System (ACCS)

Fig 91. Piston Accumulator (Type 1) Components

E - 133 9803/4160-12 E - 133

 Section E - Hydraulics

Pumps
426 Machines Removal and Replacement

!MWARNING approximately one minute, a pipe connection leakage is

indicated.
This component is heavy. It must only be removed or
handled using a suitable lifting method and device. Table 7. Torque Settings
BF-4-1_1 Item Nm kgf m lbf ft
A 244 25 180
When Removing
Release the hydraulic tank cap to vent system pressure
before removing the pump.

Disconnect all hoses and blank off to prevent ingress of

dirt.

With the pump adequately supported and the two

mounting bolts 92A removed, manoeuvre the pump so that
the splined drive shaft is clear of the engine gearbox
housing. Once the pump is clear carefully lower it to the
ground.

If it is intended to replace the pressure/flow regulator or the

drive shaft seal, follow the procedures given on
Replacing the Pressure/Flow Regulator ( E-141)
or Renewing Drive Shaft Seal ( E-142) respectively.
See Fig 98. ( E-144) for pump dismantling and
assembling procedures.

When Replacing
Fig 92.
Before refitting ensure that the pump casing has been filled
with the specified quantity of hydraulic oil.

Renew all 'O' rings.

Apply JCB Lock & Seal to the threads of bolts 92A (two
off). With the pump adequately supported engage the
pump and the splined drive shaft with the engine gearbox
housing. Fit and torque tighten bolts 92A. Ensure an exact
alignment between the pump and gearbox drive.

When all hose connections have been made run the pump
without load and allow it to deliver without pressure for a
few seconds to ensure adequate lubrication.

Run the pump to check for fluid leakage at connections. If

the pump is not delivering without air bubbles after

E - 134 9803/4160-12 E - 134

 Section E - Hydraulics
Pumps
436 Machines Removal and Replacement (Primary)

436 Machines Removal and Replacement (Primary)

!MWARNING Item
Table 8. Torque Settings
Nm kgf m lbf ft
This component is heavy. It must only be removed or A 244 25 180
handled using a suitable lifting method and device.
BF-4-1_1

When Removing
Release the hydraulic tank cap to vent system pressure
before removing the pump.

Disconnect all hoses and blank off to prevent ingress of

dirt.

With the pump adequately supported and the two

mounting bolts 93A removed, manoeuvre the pump so that
the splined drive shaft is clear of the engine gearbox
housing. Once the pump is clear carefully lower it to the
ground.

If it is intended to replace the pressure/flow regulator or the

drive shaft seal, follow the procedures given on
Replacing the Pressure/Flow Regulator ( E-141)
or Renewing Drive Shaft Seal ( E-142) respectively.
See Fig 98. ( E-144) for complete pump dismantling
and assembling procedures.

When Replacing
Before refitting ensure that the pump casing has been filled
with the specified quantity of hydraulic oil.

Renew all 'O' rings.

Apply JCB Lock & Seal to the threads of bolts 93A (two
off). With the pump adequately supported engage the
pump and the splined drive shaft with the engine gearbox
housing. Fit and torque tighten bolts 93A. Ensure an exact
alignment between the pump and gearbox drive.

When all hose connections have been made run the pump
without load and allow it to deliver without pressure for a
few seconds to ensure adequate lubrication.

Run the pump to check for fluid leakage at connections. If

the pump is not delivering without air bubbles after
approximately one minute, a pipe connection leakage is
indicated.

E - 135 9803/4160-12 E - 135

 Section E - Hydraulics
Pumps
436 Machines Removal and Replacement (Primary)

Fig 93.

E - 136 9803/4160-12 E - 136

 Section E - Hydraulics
Pumps
436 Machines Removal and Replacement (Secondary)

436 Machines Removal and Replacement (Secondary)

!MWARNING Item
Table 9. Torque Settings
Nm kgf m lbf ft
This component is heavy. It must only be removed or A 244 25 180
handled using a suitable lifting method and device.
BF-4-1_1

When Removing
Release the hydraulic tank cap to vent system pressure
before removing the pump.

Disconnect all hoses and blank off to prevent ingress of

dirt.

With the pump adequately supported and the two

mounting bolts 94A removed, manoeuvre the pump so that
the splined drive shaft is clear of the engine gearbox
housing. Once the pump is clear carefully lower it to the
ground.

If it is intended to replace the pressure/flow regulator or the

drive shaft seal, follow the procedures given on
Replacing the Pressure/Flow Regulator ( E-141)
or Renewing Drive Shaft Seal ( E-142) respectively.
See Fig 98. ( E-144) for complete pump dismantling
and assembling procedures.

When Replacing
Before refitting ensure that the pump casing has been filled
with the specified quantity of hydraulic oil.

Renew all 'O' rings.

Apply JCB Lock & Seal to the threads of bolts 94A (two
off). With the pump adequately supported engage the
pump and the splined drive shaft with the engine gearbox
housing. Fit and torque tighten bolts 94A. Ensure an exact
alignment between the pump and gearbox drive.

When all hose connections have been made run the pump
without load and allow it to deliver without pressure for a
few seconds to ensure adequate lubrication.

Run the pump to check for fluid leakage at connections. If

the pump is not delivering without air bubbles after
approximately one minute, a pipe connection leakage is
indicated.

E - 137 9803/4160-12 E - 137

 Section E - Hydraulics
Pumps
436 Machines Removal and Replacement (Secondary)

Fig 94.

E - 138 9803/4160-12 E - 138

 Section E - Hydraulics
Pumps
Tandem Pumps - 426, 436

Tandem Pumps - 426, 436

General 7 Label and disconnect the pumps outlet hoses from

the pumps. Blank off all exposed connections to
The ‘Tandem Pump Set’ is driven from the rear of the prevent the ingress of dirt.
transmission Access to the pumps is via the gap between
the rear chassis and the cab floor, or from in front of the
rear chassis. When working from the front of the rear
!MWARNING
chassis you will be working in the machines ‘Articulation This component is heavy. It must only be removed or
Zone’. Never work in this area without the Articulation Lock handled using a suitable lifting method and device.
being installed. BF-4-1_1

The pumps on the 426/436 machines share a common 8 Support the pump assembly and remove the four
suction hose. bolts B securing the pump to the transmission casing.
Carefully withdraw the pump assembly from the
Removal and Replacement transmission drive and remove from the machine.

Fig 95. ( E-140).

Replacement

The following procedure describes removal and Replacement is the reverse of the removal procedure,
replacement of the tandem pumps. however, please note the following:

1 Clean off all traces of sealant compound from the

Removal
pump and transmission housing faces. Apply a thin
bead of Loctite 5910 sealant to the transmission
!MWARNING mounting face.
Soft Ground
Note: The pump set must be assembled onto the
A machine can sink into soft ground. Never work
transmission within 15 minutes of applying the sealant.
under a machine on soft ground.
INT-3-2-4 2 Pour a small amount of clean hydraulic fluid into the
pumps inlet and outlet ports prior to installation to
1 Park the machine on firm level ground, lower the
assist with initial lubrication.
attachments to the ground. Apply the park brake, set
the transmission to neutral, stop the engine and
3 Locate the splined shaft of the pump into the
remove the starter key to prevent the machine being
transmission drive. Apply JCB Threadlocker and
started while you are working on it.
sealer to the bolts B and secure the pump set to the
transmission.
2 Install the articulation lock. Refer to Section 3 -
Routine Maintenance.
4 Torque tighten the bolts B to the values given in
Torque Settings ( E-140).
3 Block both sides of all four wheel.
5 Reconnect the pumps outlet hoses as detailed in
4 Carry out the hydraulic pressure venting procedure
Connecting and Disconnecting Hydraulic
as detailed. Venting the Hydraulic
Hoses ( E-103).
Pressure ( E-102)
Note: All hydraulic adaptors that are installed together with
5 Drain the hydraulic fluid from the hydraulic tank.
a bonded sealing washer must also have JCB Threadseal
sealant applied to the threads of the adaptor.
6 Remove the four flange bolts A securing the suction
hose flange to the pump body. Blank off the exposed
connections to prevent the ingress of dirt.

E - 139 9803/4160-12 E - 139

 Section E - Hydraulics
Pumps
Tandem Pumps - 426, 436
6 Fit a new sealing O-ring to the suction hose flange. 8 When all hose connections have been made run the
Reconnect the pumps suction hose flange to the pump without load and allow it to deliver without
pumps body with bolts A. pressure for a few seconds to ensure adequate
lubrication.
7 Fill the hydraulic tank with the correct grade of
hydraulic fluid. Section 3 - Routine Maintenance. 9 Check the main and stand-by pressures as detailed in
Tandem Pumps ( E-112).
Note: Replace the suction strainer and return line filter if
fitting a new or serviced pump set. Table 10. Torque Settings
Item Nm kgf m lbf ft
B 130 13.26 95.8




Fig 95.

E - 140 9803/4160-12 E - 140

 Section E - Hydraulics
Pumps
Replacing the Pressure/Flow Regulator

Replacing the Pressure/Flow Regulator

Remove the capscrews 96-1 (four off) and detach the 'O' rings 96-3 are fitted in the regulator body before
regulator 96-2 from the pump housing. An unserviceable assembly to the pump.
regulator must be replaced with a new item. Ensure new

Fig 96.

E - 141 9803/4160-12 E - 141

 Section E - Hydraulics
Pumps
Renewing Drive Shaft Seal

Renewing Drive Shaft Seal

Remove the retaining ring 97-1. Remove the shaft seal 97-
2, (note positioning of seal grooved face as an aid to
refitting). Remove the 'O' ring 97-3 from pump housing.

Examine the seal running area (drive shaft and housing)

for wear or damage. Damage in these areas will require
the pump to be further dismantled as shown on Fig
98. ( E-144).

Lubricate a new seal with Mobilplex or equivalent grease

containing Molybdenum Disulphide. Fit new seal ensuring
it enters the housing evenly and with the grooved face
correctly positioned. Position a new 'O' ring on the pump
housing.

Fig 97.

E - 142 9803/4160-12 E - 142

 Section E - Hydraulics
Pumps
Dismantling, Inspecting and Assembly

Dismantling, Inspecting and Assembly

Note: The pump shown is the machine primary pump. The The cradle 98-12 is correctly positioned with its lubrication
secondary pump is similar in design and construction and bore on the high pressure side.
should be dismantled and assembled in a similar
sequence.

The numerical sequence shown on the illustration is

intended as a guide to dismantling and assembly.

Before dismantling the pump make sure the exterior of the

pump and the working area is thoroughly clean and free
from possible sources of contamination.

Dismantling
During dismantling note the following:

Mark covers and housing to ensure correct replacement.

Use a soft-faced hammer to separate components. Do not
use levers or other tools that may damage machined
surfaces.

The port plate 98-2 is removed complete with the control

plate 98-6 and control pistons 98-8 and 98-9.

The rotary group 98-3 is removed complete with shaft 98-

11, taper bearing races 98-10, 98-13 and cradle 98-12.

Remove the outer bearing races from the port plate and
pump casing only if unserviceable and need to be
renewed.

Inspecting
Generally check all pump parts for damage and/or wear.
The shaft 'O' ring grooves and all sealing faces must be
free of burrs and scores. Carry out a check for free running
of the rotary group and control pistons during assembly.

Assembly
For assembly the sequence should be reversed but note
the following:

Renew all 'O' rings.

Apply JCB Lock & Seal to the securing threads of the

control pistons 98-8 and 98-9.

E - 143 9803/4160-12 E - 143

 Section E - Hydraulics
Pumps
Dismantling, Inspecting and Assembly

Fig 98.

E - 144 9803/4160-12 E - 144

 Section E - Hydraulics

Emergency Steering
426 from S/N 532847, 436 from S/N 534469

Removal and Replacement 6 Tag and disconnect the electrical cables 99C from
their connection to the motor.

!MWARNING Note: Cable X = Power Supply from the Starter Motor

Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the Note: Cable Y = Earth Connection to the Engine
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of 7 Support the weight of the combined pump and motor
cardboard close to suspected leaks and then inspect assembly and release the two clamps 99D securing
the cardboard for signs of fluid. If fluid penetrates your the assembly to the bracket and remove.
skin, get medical help immediately.
INT-3-1-10_2
Replacement

Replacement is the reverse of removal, however note the

!MWARNING following:
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Whenever the pump or motor assembly has been
Before disconnecting or connecting hydraulic hoses, replaced, repaired or disturbed, the system pressure must
stop the engine and operate the controls to release be checked and set in accordance with the procedure
pressure trapped in the hoses. Make sure the engine described in Checking/Adjusting the System
cannot be started while the hoses are open. Pressure ( E-125).
INT-3-1-11_1

Removal

1 Park the machine on firm level ground and lower the

loader arms. Engage the parking brake. Put the
transmission into neutral and chock both sides of all
four wheels. Stop the engine. Operate the hydraulic
control levers to release any pressure trapped in the
hoses. Slowly remove the hydraulic tank filler cap to
vent any residual pressure. Refit the filler cap.

2 Open the right hand engine cover.

3 Disconnect the batteries, to prevent the engine being

started or the ignition being turned on whilst working
on the emergency steer system.

4 Tag and disconnect the hydraulic hoses 99A from the

steering pump. Cap the open ports and hoses top
prevent dirt ingress.

5 Disconnect the “system at pressure” pressure switch

99B electrical connection to the pump valve.

E - 145 9803/4160-12 E - 145

 Section E - Hydraulics
Emergency Steering
426 from S/N 532847, 436 from S/N 534469

Fig 99.

E - 146 9803/4160-12 E - 146

 Section E - Hydraulics
Cooling Fan Motor
436 from M534200

Cooling Fan Motor

436 from M534200

Removal and Replacement 8 Lift the framework complete with the fan motor and
blades from the machine.
Removal
9 Remove the bolts 100-3 securing the fan blades to
1 Park the machine on firm level ground and lower the the motor and remove the fan blades.
loader arms. Engage the parking brake. Put the
transmission into neutral and chock both sides of all 10 Remove the bolts 100-4 securing the fan motor its
four wheels. Stop the engine and let it cool down. framework and remove the fan motor.
Operate the hydraulic control levers to release any
pressure trapped in the hoses. Slowly remove the Replacement
hydraulic tank filler cap to vent any residual pressure.
Refit the filler cap. Replacement is the reverse of removal.

2 Open the rear grille and remove the reverse alarm

from its mounting by removing the two securing bolts.

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

4 Secure slings to the rear pod and using the overhead

crane lift the pod away from the machine.

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2

5 Disconnect the hydraulic hoses to the fan motor. If Fig 100.

there are no tags on the hoses tie on your own to aid
refitment. Cap the open ports and hoses.

6 Remove the bolts 100-1 securing the fan guards to

the cooling pack cowl and to the motor framework.
Remove the fan guards.

7 Remove the bolts 100-2 securing the fan motor

framework to the cooling pack cowl.

E - 147 9803/4160-12 E - 147

 Section E - Hydraulics
Cooling Fan Motor
436 from M534200
Dismantling, Inspection and
Assembly

E - 148 9803/4160-12 E - 148

 Section E - Hydraulics
Cooling Fan Motor
436 from M534200

E - 149 9803/4160-12 E - 149

 Section E - Hydraulics
Cooling Fan Motor
436 from M534200

E - 150 9803/4160-12 E - 150

 Section E - Hydraulics
Cooling Fan Motor
436 from M534200

E - 151 9803/4160-12 E - 151

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

426 from 1231500, 436 from 1305000

Removal !MWARNING
Note: The following procedure’s illustrations depict a Uni- Hydraulic Pressure
Directional Motor; the Bi-Directional motor has an Hydraulic fluid at system pressure can injure you.
additional hose. In all other aspects the procedures are the Before disconnecting or connecting hydraulic hoses,
same. stop the engine and carry out the full venting
procedure. Make sure the engine cannot be started
1 Park the machine on firm level ground, lower the while the hoses are open.
attachments to the ground, apply the park brake and INT-3-1-18
set the transmission to neutral. Stop the engine. Block
both sides of all four wheels. 6 Label and disconnect the hoses 103A and 103B to
the cooling fan motor. plug the hoses and cap the
Important: The procedure detailed below must be open motor ports to prevent the ingress of dirt or
followed to correctly vent the residual hydraulic pressure. debris. Connecting and Disconnecting
Hydraulic Hoses ( E-103).
2 Vent the hydraulic pressure as detailed in Venting
the Hydraulic Pressure ( E-102).

3 Disconnect the batteries to prevent the engine being

started whilst carrying out this procedure.

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

From inside the right-hand side cover pull the release
cable 102A to unlatch the rear fan housing assembly.


Fig 103. Uni-Directional Motor

7 Open the fan housing and remove the four bolts 104A
securing the inner guard to the housing and remove
the guard.

Fig 102.

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

E - 152 9803/4160-12 E - 152

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

Replacement
Replacement is the reverse of the removal procedure,
however note the following:

!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
 cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
 INT-3-1-10_2

1 Take care to secure the hydraulic hoses inside the fan

housing to prevent possible contact with the fan.

 2 Top up the hydraulic fluid as necessary with the

 correct grade of fluid. Refer to Section 3 - Routine
Maintenance.
Fig 104.

8 Remove the four bolts 104B securing the fan blades

to the motor hub and remove the fan. Store the fan
carefully so as not to damage the blades. (Do not refit
a fan with damaged blades.)

9 Lower the fan housing to the closed position and

remove the two Allen bolts 105A securing the fan
motor to the spider and remove the motor.

Fig 105.

E - 153 9803/4160-12 E - 153

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000
Uni-Directional Motor

E - 154 9803/4160-12 E - 154

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

E - 155 9803/4160-12 E - 155

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

E - 156 9803/4160-12 E - 156

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

E - 157 9803/4160-12 E - 157

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000
Bi-Directional Motor

E - 158 9803/4160-12 E - 158

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

E - 159 9803/4160-12 E - 159

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

E - 160 9803/4160-12 E - 160

 Section E - Hydraulics
Cooling Fan Motor
426 from 1231500, 436 from 1305000

E - 161 9803/4160-12 E - 161

 Section E - Hydraulics

Rams
Precautions During Use
TE-006

Installation Special seal materials are necessary so check to

see if the ram that you are using is suitable or not.
1 Precautions when installing the ram on the machine.
c The number one cause of ram oil leakage is rod
a When installing and removing from the machine, damage. Be careful not to damage the rod.
suspend the ram safely.
2 Warm up sufficiently before beginning work.
b Suspending the ram by the piping is not only
dangerous, but can also cause damage to the a In cold conditions the rod seals may be frozen, so
cylinder. if the ram is operated at maximum pressure and
maximum speed, the seals will be damaged.
c Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. Also, b There is a large amount of air in a new ram or one
the rod can be damaged and become unusable. which has been left for a long time, so the ram will
not operate smoothly. Also, if pressure is applied
2 Welding after installing the ram may result in damage. suddenly without bleeding the air, high
temperatures will be generated due to adiabatic
a If electric welding is done even at a point away compression and the seals may burn.
from the ram, there may be sparking inside the
ram and it will become necessary to replace the c Before beginning work, always move the ram at
ram with a new one. full stroke with no load and expel air from the
cylinder.
3 When painting the machine, mask the ram.
3 When stopping or storing, do it at a safe and fixed
a If paint adheres to the rod surface or to the wiper position.
ring and the ram is operated, the wiper ring will not
function properly and foreign matter and paint can a The installed ram cannot maintain the same
easily enter the ram. This will cause damage to position for a long period of time, because the oil
the seals, drastically shortening the life of the ram. inside the ram may leak and the hydraulic oil
volume decreases as it cools. Stop or store the
4 Install the ram only when it is clean. machine in a safe and fixed position.

Caution During Use Maintenance, Inspection Points

1 Use only under designated conditions. 1 Carry out daily maintenance and inspection.

a If hydraulic oil other than the designated oil is a The key point for correct long-term ram function is
used, the seals quickly degenerate and become daily maintenance and inspection. Carry out
damaged. If the relief valve is set at a value higher maintenance and inspection so that the ram
than specified, it may cause ram damage and is functions fully at all times. Always remove any
dangerous. mud, water, dust or oil film adhering to the rod and
keep it in normal condition. However, when
b In high temperature environments (approx. 90°C cleaning the wiper ring and seals, do not get them
and above) or low temperature environments wet with water but wipe clean with a rag. To
(below -20°C), seals quickly become damaged. prevent rust forming during storage, the amount of
exposed ram piston rod should be kept to a

E - 162 9803/4160-12 E - 162

 Section E - Hydraulics
Rams
Precautions During Use
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.

a 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.

a 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.

b 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.

c 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.

E - 163 9803/4160-12 E - 163

 Section E - Hydraulics
Rams
Typical Ram

Typical Ram

Dismantle and Assembly

Fig 109. ( E-165). The numerical sequence shown on
the illustration is intended as a guide to dismantling.

Dismantle

1 Place ram assembly on a locally manufactured strip/

rebuild bench. Fig 108. ( E-164).

Fig 108.

2 Use the correct size spanner to release end cap 109-

1 and remove the piston rod assembly 109-9 from the
cylinder.

!MWARNING
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD-1-2

3 Position piston rod assembly on bench in place of ram

cylinder. Remove seals 109-5, 109-6 and wear ring
109-4, 109-7 from piston head 109-3.

4 Extract dowel 109-2 from the piston head using the

appropriate sized screw threaded into the extractor
hole.

5 Use the correct size spanner, remove piston head

109-3 from rod 109-9 and remove ‘O’ ring 109-8.

6 Remove gland bearing and end cap 109-1 from

piston rod and remove the ‘O’ ring 109-10, wiper seal
109-12 and rod seal 109-11. Check end cap bearing
for damage, scores or nicks. If damaged, the bearing
must be replaced as part of the end cap assembly.

7 Ensure that metal components are free from scoring,

nicks and burrs. A damaged piston rod will impair the
life of the gland seals. Check the bore of the ram
cylinder for damage.

E - 164 9803/4160-12 E - 164

 Section E - Hydraulics
Rams
Typical Ram

Fig 109. Typical Ram

E - 165 9803/4160-12 E - 165

 Section E - Hydraulics
Rams
Typical Ram
Assemble Table 16. Torque Settings
Ram size Item Nm kgf m lbf ft
1 Clean threads of piston rod, piston head, end cap and All except 60 x 30 & 50 1 678 69 500
cylinder using a wire brush. Use JCB Cleaner and x 25
Degreaser to ensure that all threads are free from
grease, hydraulic oil and old sealing/retaining All except 60 x 30 & 50 3 405 41 300
compounds. Allow 15 minutes for solvent to dry x 25
before applying JCB Threadlocker and Sealer (High 60 x 30 only 1 450 46 332
Strength).
60 x 30 only 3 300 31 221
Important: Ensure that seals or ‘O’ rings do not come into 50 x 25 only 1 400 41 295
contact with JCB Activator or anaerobic sealing and 50 x 25 only 3 250 25 184
retaining compounds such as JCB Threadlocker and
Sealer.

2 Fit new seals, ‘O’ rings and wear rings.

For the correct method of fitting seals to the end cap

and piston head, JCB Ram Sealing
Procedure ( E-167).

Important: Ensure that lubricants used during assembly

do not come into contact with degreased components or
sealing/retaining compounds.

3 Fit locking dowel 109-2 to piston 109-3. Piston

Head Retention ( E-169).

4 Position cylinder 109-19 on the bench and install the

piston rod assembly into the cylinder.

5 Apply JCB Activator to threads of end cap and

cylinder. Allow JCB Activator to dry for 15 minutes
before bringing into contact with JCB Threadlocker.

6 Apply JCB Threadlocker to threads of cylinder and

torque tighten end cap 109-1. Table 16. Torque
Settings ( E-166).

Note: If hydraulic oil contacts uncured JCB Threadlocker a

weakening of the bond will result. Cure times vary
according to the ambient temperature. The following
approximate cure time applies at 20 °C and is the minimum
period between assembly and filling the ram with oil.

JCB Threadlocker & Sealer (High Strength) or JCB

Threadlocker with JCB Activator - 1 hour.

Note: Cold weather operation. When operating in

conditions which are consistently below freezing, it is
recommended that the rams are operated slowly to their
full extent before commencing normal working.

E - 166 9803/4160-12 E - 166

 Section E - Hydraulics
Rams
Typical Ram

JCB Ram Sealing Procedure

TE-005

1 Fit new rod seals.

Use seal fitting tool 110-A to fit rod seals, the size
(diameter) and position of pins 110-B is determined
by the diameter and radial width of the rod seal being
fitted.

Fig 112.

b Close the tool. Fig 113. ( E-167). The seal

must form a reniform (kidney shape).

Fig 110. Seal Fitting Tool

The pins are screwed into threaded holes in the tool

body, the spacing of the holes is designed to suit
small or large diameter rod seals.

a Open the tool and insert the new rod seal 111-A. Fig 113.
The seal must be fitted behind the two front pins
but in front of the rear pin as shown. c Before fitting the rod seals check the seal grooves
are free of contamination and sharp edges.

d Locate the seal in the end cap groove. Fig

114. ( E-167). When the seal is in position,
open the tool to release the seal. Make sure the
seal is correctly installed in its grooved and
remove the tool.

Fig 111.

Note: Later ram end caps and piston heads are metric
threads. The seals are also different, make sure the
correct seals are fitted. On metric threaded rams make
sure the seals are fitted the correct way round, as shown
at 112-A and 112-B.

Fig 114.

e Fit rod wiper seal 112-A into seal groove. Make

sure the seal is correctly installed as shown.

Note: Some rod wipers, i.e. power track rod, may use a
metal encased seal which is pressed into the housing.

E - 167 9803/4160-12 E - 167

 Section E - Hydraulics
Rams
Typical Ram
Care must be taken to ensure the seal is square before it c Ensure the O-ring is fitted into the internal seal
is pressed in. groove on the piston head. Screw the piston head
onto the thread of the piston rod, refer to the
f Sleeve 115-A must be used to protect the rod relevant section for torque figure and completion
seals from damage when fitting end cap onto the of ram assembly.
piston rod. There are various sizes of sleeve, see
Service Tools, Section 1. Make sure the hexagon d Fit the piston head retaining dowel, refer to the
on the end cap is towards the eye end of the rod. relevant section for torque figure and completion
of ram assembly.

e Fit wear rings 117-A and 117-B. Rotate the wear

rings so that the piston retention dowel is covered
by the wear ring, Not as shown at 117-C.

Fig 115.

2 Fit new head piston seals.

a Use a blunt instrument 116-A (Part no. 892/

01027) to lever the inner seal 116-B into the
piston head seal groove. Do not let the seal twist.
There are identification marks on the outer
diameter of the seal, make sure the marks are
visible and the seal is free to rotate, if not remove
the seal and refit. Fig 117.

3 Fit the piston rod and head assembly into the cylinder.

a Insert the piston/rod assembly into the cylinder.

Align the rod and head assembly until parallel with
the cylinder then push the assembly into the
cylinder.

b Fit the end cap, refer to the relevant section for

torque figure and completion of ram assembly.

Fig 116.

b Fit outer seal 116-C using the same procedure as

stated for seal 116-B. Check the external grooves
are visible.

E - 168 9803/4160-12 E - 168

 Section E - Hydraulics
Rams
Typical Ram

Piston Head Retention Drilling Dimensions

Fit locking dowel to piston as follows:

Existing piston head and rod

Align holes so that dowel can be fitted with tapped

extractor hole showing.

New piston head and rod

Drill and ream piston head and rod to the diameter and
depth indicated. Drilling Dimensions ( E-169).
Remove all swarf and contamination and insert dowel with
tapped extractor hole showing.

Note: Ensure that the top of the dowel is below the level of
the bearing ring groove and use an undersized pilot drill
before drilling to the final size shown in the table.
Fig 118.
Existing piston head and new rod
Table 17. Drill Depth Chart
Drill through existing hole in piston head to the diameter Ram Diameter X Depth Y
and depth indicated. Drilling Dimensions ( E-169). size
Remove all swarf and contamination and insert dowel with 90 x 50 8.02mm - 8.10mm 27.0mm - 28.0mm
tapped extractor hole showing.
60 x 30 6.02mm - 6.10mm 22.0mm - 23.0mm
Note: Ensure that the top of the dowel is below the level of 100 x 60 8.02mm - 8.10mm 27.0mm - 28.0mm
the bearing ring groove and use an undersized pilot drill
70 x 40 6.02mm - 6.10mm 22.0mm - 23.0mm
before drilling to the final size shown in the table.
80 x 50 6.02mm - 6.10mm 22.0mm - 23.0mm
New piston head and existing rod 50 x 25 6.02mm - 6.10mm 22.0mm - 23.0mm
130 x 70 12.02mm -12.10mm 37.0mm - 38.0mm
Same as Existing piston head and new rod but at 90
degrees to existing hole in rod. 110 x 60 12.02mm -12.10mm 32.0mm - 33.0mm
110 x 65 12.02mm -12.10mm 32.0mm - 33.0mm
140 x 75 12.02mm -12.10mm 47.0mm - 48.0mm

E - 169 9803/4160-12 E - 169

 Section E - Hydraulics
Rams
Z Rams

Z Rams

Z Ram gland seal from damage and secure end cap onto the
piston rod 119-9.
The numerical sequence shown on Fig 119. ( E-171)
is intended as a guide to dismantling. Fit a new 'O' ring 119-12 into piston head 119-8.

Dismantling Assemble piston head 119-8 onto piston rod and torque
tighten.
Place ram assembly on a locally manufactured strip/
rebuild bench as shown. Fit grub screw 119-4 and ball 119-5 to piston.

Remove 8 off bolts 119-2 and washers 119-3 to release Fit new seal 119-6 to piston head 119-3 then fit outer seal
end cap 119-1 and remove the piston rod assembly 119-9 119-5 over piston seal 119-6.
from the cylinder.
Fit seal 119-10 and bearings 119-12 to piston head.

!MWARNING Position cylinder on bench and install rod assembly into

cylinder.
If air or hydraulic pressure is used to force out the
piston assembly, ensure that the end cap is securely
fitted. Severe injury can be caused by a suddenly
released piston rod.
HYD-1-2

Position piston rod assembly on bench in place of ram

cylinder. Remove seal 119-10 and bearings 119-12 from
piston head 119-8.

Extract grub screw 119-4 and ball 119-5 from the piston
head.

Use the correct size spanner, remove piston head 119-8

from rod 119-9 and remove 'O' ring 119-12.

Ensure that metal components are free from scoring, nicks

and burrs. A damaged rod will impair the life of the gland
seal.

Assembly

Clean threads of piston rod, piston head, end cap and

cylinder using a wire brush.

Use JCB Super Clean Safety Solvent to ensure that all

threads are free from grease, hydraulic oil and old Loctite.
Allow 15 minutes for solvent to dry.

Fit new “0” ring 119-15, seal 119-19 and wiper 119-19 into
end cap 119-1, make sure the seal 19 and wiper 119-18
are fitted as shown at A and B. Use sleeve C to protect the

E - 170 9803/4160-12 E - 170

 Section E - Hydraulics
Rams
Z Rams

Fig 119.

E - 171 9803/4160-12 E - 171

 Section E - Hydraulics
Rams
436ZX Ram

436ZX Ram

The following information is for rams used on wheeled 3 Position the cylinder vertically ( Fig
loading shovel machines as detailed below: 122. ( E-172)).

Machine Ram Description

436ZX Shovel 160/80

Dismantling the piston rod from cylinder

tube
Necessary equipment

Assembly bench

Overhead crane

Cleaning facilities

Socket wrench

Note: Disassembly should be done vertically.

1 Clean the cylinder carefully. Use high-pressure

cleaning and solvent ( Fig 120. ( E-172)). Empty
the oil from the cylinder.

Fig 120.

2 Unfasten the cylinder head screws. Keep screws in

place ( Fig 121. ( E-172)).

Fig 122.

4 Release the end cover and pull out the piston rod
pack.

Note: Handle the piston rod with care to avoid damage.

Put some soft material between piston rod and shims
Fig 121.

E - 172 9803/4160-12 E - 172

 Section E - Hydraulics
Rams
436ZX Ram
during transport and at storage. Fasten the covers for the
end flange.

Dismantling the piston rod

Note: protect all the parts from dirt.

1 Secure the piston rod pack on the bench, brace the

piston rod head ( Fig 123. ( E-173)).

Fig 126.

5 Press the cushion ring against the piston ( Fig

Fig 123. 127. ( E-173)).

2 Unfasten and remove the stop screw 124X. Remove

the steel ball 124Y ( Fig 124. ( E-173)).

Fig 127.

Fig 124. 6 Dismantle the lock halves ( Fig 128. ( E-173)).

3 Unfasten the nut ( Fig 125. ( E-173)).

Fig 125.

4 Dismantle the snap ring by carefully knocking on it

with a plastic hammer ( Fig 126. ( E-173)).

Fig 128.

E - 173 9803/4160-12 E - 173

 Section E - Hydraulics
Rams
436ZX Ram
7 Remove the cushion ring ( Fig 129. ( E-174)).

Fig 132.

Fig 129.

8 Remove the seal ( Fig 130. ( E-174)).

Fig 130.

9 Remove the shims 131A, the piston 131B, the

cushion ring 131C and disassemble the cushion ring
seal 131D ( Fig 131. ( E-174)).

Fig 131.

10 Dismantle the cylinder head.

Note: Protect the threads ( Fig 132. ( E-174)).

E - 174 9803/4160-12 E - 174

 Section E - Hydraulics
Rams
436ZX Ram

Removing the piston seals

Note: Never reuse seals

While dismantling, handle the piston very carefully.

1 Remove the four slotted guiding rings and the two

back up rings from the piston ( Fig
133. ( E-175)).

Fig 133.

2 Turn the sharp edge of the scalpel against the slide

ring and press it down into the small gap between
piston and slide ring ( Fig 134. ( E-175)). Lift the
O-ring with a chisel and cut it off.

Fig 134.

Take care not to damage the surface.

E - 175 9803/4160-12 E - 175

 Section E - Hydraulics
Rams
436ZX Ram

Removing the cylinder head seals

1 The cylinder head wiper is disassembled by
deforming it with a hammer and chisel according to
( Fig 135. ( E-176)).

Fig 137.

Note: Do not put the chisel in too far, the surfaces of the
head are galvanised.
Fig 135.
4 Cut the primary seal with a scalpel ( Fig
2 Press a sharp object into the back up ring (Pos. 1) at 138. ( E-176)). After that, the chisel may be used to
its slit, bend out and pull away the back up ring with remove the back up ring.
pliers ( Fig 136. ( E-176)).

Fig 138.
Fig 136.
Note: Do not cut through, the surfaces of the cylinder head
3 The secondary seal (Pos. 2) is removed using a are easily damaged.
chisel. Put the chisel into the small gap where the
back up ring was earlier, bend out ( Fig 5 Remove the O-ring using a sharp tool. Press the tool
137. ( E-176)). through the square ring and bend out ( Fig
139. ( E-177)).

E - 176 9803/4160-12 E - 176

 Section E - Hydraulics
Rams
436ZX Ram

Fig 139. Fig 141.

6 Turn the cylinder head and remove the snap ring with
a chisel ( Fig 140. ( E-177)).

Fig 140.

7 Remove the O-ring and back up ring for the external

seal. Use a chisel ( Fig 141. ( E-177)).

E - 177 9803/4160-12 E - 177

 Section E - Hydraulics
Rams
436ZX Ram

Fig 142.

8 To remove the bush in the cylinder head, an expander

tool is required. Fit the expander tool 142A in the
cylinder head 142B according to Fig
142. ( E-178). Please note the direction! Press the
tool in far enough, so that the rifled part is opposite
the bush.

Assemble the guide jig 142C and the screw 142D.

Extend the flutes in the expander tool using the Allen

key.

9 Put the cylinder head on the press rod ( Fig

143. ( E-178)). Press out the expander tool which
will then remove the bush.

Fig 143.

E - 178 9803/4160-12 E - 178

 Section E - Hydraulics
Rams
436ZX Ram

Assembling the piston seals 3 Assembly of slide ring

Before assembly Set up according to Fig 146. ( E-179).

1 To assemble the piston seals use a seal insertion tool.

Make sure the tool is free from defects. Burrs or
marks may damage the seals and cause leakage.
Check the outside of the tool carefully.

One part of the seal insertion tool is thin-walled, make

sure it is not damaged ( Fig 144. ( E-179)).

Fig 144.

2 Carefully place seal insertion tool on the piston and

roll on the O-ring until it is placed in the middle groove Fig 146.
of the piston.
A Plate
Make sure the O-ring is not twisted after assembly
B Outer guide jig
( Fig 145. ( E-179))
C Slide ring.
D Inner guide jig, (heated to approximately 60ºC).
E Piston.

4 Pressing of slide ring

Use the press to press the slide ring down into the
middle groove of the piston (where the O-ring already
is). During pressing, the outer guide jig must be held
together with one hand ( Fig 147. ( E-180)). The
slide ring will open out at this stage.

Fig 145.

E - 179 9803/4160-12 E - 179

 Section E - Hydraulics
Rams
436ZX Ram

Fig 149.
Fig 147.
7 Check the piston seal.
5 Assembling the back up rings.
Press the piston through the correction jig ( Fig
150. ( E-180)).
Attach the green back up rings, make sure that their
slits are not aligned ( Fig 148. ( E-180)).

Fig 150.

Fig 148. 8 Fit slotted guiding rings.

6 Use the correction jig to calibrate the seals. Please Note: Guiding ring slits must not be aligned! ( Fig
note the direction of the jig! ( Fig 149. ( E-180)) 151. ( E-181)).

E - 180 9803/4160-12 E - 180

 Section E - Hydraulics
Rams
436ZX Ram

Fig 151.

E - 181 9803/4160-12 E - 181

 Section E - Hydraulics
Rams
436ZX Ram

Assembling the cylinder head seals 3 Fitting of primary seal and U-ring.

Before assembly Turn the head to get the wiper end up and clean.
Attach the square ring.
Check that assembly tools are free from defect. Clean
tools before starting the set. Pre-heat the U-ring to Note: Please check the correct direction!
approximately. 60ºC. Clean cylinder head before
assembly. Check that grooves are clean and not damaged.

1 Fitting of bushing and snap ring.

Set up according to Fig 152. ( E-182). Press in

the bush using the press rod. Attach snap ring.

Fig 154.

A Back up Ring (green).

B Side Ring (black).
C Square ring.

Bend the slide ring to a loose curve before fitting,

( Fig 155. ( E-183)). Please note the right
direction!

Fig 152. Fit back up ring after putting the slide ring in place.

2 Fit O-ring and back up ring ( Fig 153. ( E-182)). 4 Attach the back up ring first.

Bend the U-ring according to Fig 155. ( E-183).

Fig 153.

E - 182 9803/4160-12 E - 182

 Section E - Hydraulics
Rams
436ZX Ram

Fig 155.

Insert the U-ring under the back up ring.

Fig 158.

A Wiper
B Square Ring
C Back Up Ring (Green)
D Slide Ring (Black)
E Back Up Ring
Fig 156.
F Secondary Seal
5 Fitting of wiper. G Bushing
H Snap Ring
Use the plate to press in the wiper ( Fig
157. ( E-183)). J Back Up Ring
K O-Ring

Fig 157.

6 Complete pre-assembled head ( Fig

158. ( E-183)).

E - 183 9803/4160-12 E - 183

 Section E - Hydraulics
Rams
436ZX Ram

Assembly of piston rod with cushion before seal assembly and be kept clean up until this stage.
Do not clean piston or cylinder head with seals fitted.
ring on the piston rod side
The cylinder components must be cleaned before
assembly. The piston and cylinder head must be cleaned

Fig 159. Fully assembled piston rod

Fig 160. Piston rod

Fig 162.

2 Fit the seal under the cushion ring ( Fig

163. ( E-185)).

Please note the direction!

Fig 161. Cylinder head guide

1 Fit the cylinder head on ( Fig 162. ( E-184)).

E - 184 9803/4160-12 E - 184

 Section E - Hydraulics
Rams
436ZX Ram

Fig 163. Fig 166.

3 Put the cushion ring on ( Fig 164. ( E-185)). 6 Assemble and tighten the nut to the torque value
according. ( Fig 167. ( E-185)).
Please note the direction! Turn the arrow point
towards the piston. Ram Torque
436ZX Shovel 160/80 7500Nm (5532 lbf ft) (765
kgf m)

Fig 164.

4 Put the piston on. Please note the direction! ( Fig

165. ( E-185)). Fig 167.

7 Fit the steel ball 168-7 ( Fig 168. ( E-185)).

Fig 165.

5 Fit shims (reduction of friction) ( Fig Fig 168.

166. ( E-185)).
8 Fit the stop screw ( Fig 169. ( E-186)).

Tighten to 46.2 to 67.6 Nm (34.1 to 49.8 lbf ft) (4.7 to

6.8 kgf m).

E - 185 9803/4160-12 E - 185

 Section E - Hydraulics
Rams
436ZX Ram

Fig 169.

Make two punch marks by the stop screw so that the

material is clearly indented ( Fig 170. ( E-186)).

Fig 170.

E - 186 9803/4160-12 E - 186

 Section E - Hydraulics
Rams
436ZX Ram

Assembly of piston rod with cushion assembly and be kept clean up until this stage. Do not
clean piston or cylinder head with seals fitted.
ring on the piston rod and cylinder
bottom side
Cylinder components must be cleaned before assembly.
Piston and cylinder head must be cleaned before seal

Fig 171. Fully assembled piston rod

1 Put the cylinder head on ( Fig 174. ( E-187)).

Fig 172. Piston rod

Fig 174.

2 Fit the seal for the front cushion ring ( Fig

175. ( E-188)).

Fig 173. Cylinder head guide Please note the direction!

E - 187 9803/4160-12 E - 187

 Section E - Hydraulics
Rams
436ZX Ram

Fig 175. Fig 178.

3 Put the front cushion ring on. Please note the 6 Fit the seal for the rear cushion ring ( Fig
direction! 179. ( E-188)).

Warning! Turn arrow point towards the piston ( Fig Please note the direction!
176. ( E-188))

Fig 179.
Fig 176.
7 Fit the rear cushion ring. Please note the direction!
( Fig 180. ( E-188))
4 Fit the piston ( Fig 177. ( E-188)). Please note
the direction!
Note: Turn arrow point towards the piston.

Fig 177.
Fig 180.
5 Fit shims ( Fig 178. ( E-188)).
8 Press in the rear cushion ring as far as possible
( Fig 181. ( E-189)).

E - 188 9803/4160-12 E - 188

 Section E - Hydraulics
Rams
436ZX Ram

Fig 181. Fig 184.

Assemble the two lock halves and hold them with 10 Fit and tighten the nut to stated torque value as
your fingers. Use the other hand to put the rear follows: ( Fig 185. ( E-189)).
cushion ring over the two halves ( Fig
182. ( E-189)). Note: Do not use oil!

Ram Torque
436ZX Shovel 160/80 7500Nm (5532 lbf ft) (765
kgf m)

Fig 182.

The rear cushion ring keeps the lock halves in place

( Fig 183. ( E-189)).

Fig 185.

11 Fit the steel ball ( Fig 186. ( E-189)).

Fig 183.

9 Carefully knock the snap ring in place.

Use a plastic hammer ( Fig 184. ( E-189)). Fig 186.

12 Fit stop screw ( Fig 187. ( E-190)).Tighten to

46.2 to 67.6 Nm (34.1 to 49.8 lbf ft) (4.7 to 6.8 kgf m).

Make two punch marks on each side of the stop

screw so that the material is clearly bent

E - 189 9803/4160-12 E - 189

 Section E - Hydraulics
Rams
436ZX Ram

Fig 187.

E - 190 9803/4160-12 E - 190

 Section E - Hydraulics
Rams
436ZX Ram

Assembly of piston rod in cylinder tube

1 Make sure that assembly tools and cylinder tube are
clean before assembly. The piston rod pack must be
protected from dirt up until this stage. Assembly
should be made vertically.

Secure the cylinder tube ( Fig 188. ( E-191)) and

bring the end of the piston rod to the cylinder tube
opening.

Fig 189.

3 Put the piston rod pack into the cylinder tube. Make
sure that the piston guiding ring does not get jammed
during assembly.

Clean hydraulic oil will help, but do not use a brush as

hairs may come off.

When running the piston rod in, turn the cylinder head
into the right position. Finish doing this before the
cylinder head O-ring has reached the cylinder tube
( Fig 190. ( E-192)). Do not use assembly
grease.

Fasten the cover.

Fasten cylinder head screws and torque tighten to the

following values:

Ram Torque
436ZX Shovel 160/80 440Nm (324 lbf ft) (44.8 kgf
m)

Fig 188.

Release the end-flange cover on the cylinder tube in

order to let air out from the tube during assembly.

Make sure the piston rod head is turned in the right

position in relation to the bottom of the cylinder.

2 Before assembly, make sure that guiding slits on the

piston are not aligned ( Fig 189. ( E-191)).

E - 191 9803/4160-12 E - 191

 Section E - Hydraulics
Rams
436ZX Ram

Fig 190.

4 Tighten in order according to Fig 191. ( E-192).

Note: Be careful not to damage the piston rod!

Fig 191.

E - 192 9803/4160-12 E - 192

Section F

Transmission
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-12



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section F - Transmission

Page left intentionally blank

F-0 9803/4160-12 F-0

 Section F - Transmission

Contents Page No.

Technical Data
426 and 436 ............................................................................................ F - 1
Drive Axle - Front & Rear ................................................................... F - 1
Transmission ...................................................................................... F - 3

Powershift Transmission
WG 150, WG 200 .................................................................................... F - 6
Control Valve ...................................................................................... F - 6
Charge Pump ................................................................................... F - 13
Coaxial Power Take-off .................................................................... F - 18
Lateral Power Take-off ..................................................................... F - 21
Layshaft ............................................................................................ F - 24
Final Drive ........................................................................................ F - 26
Multi-Disc Clutches ........................................................................... F - 30
Clutch K4/K3 .................................................................................... F - 32
Clutch KR/K2 .................................................................................... F - 35
Clutch KV/K1 .................................................................................... F - 37
Emergency Steering Pump ............................................................... F - 39
WG 160, WG 190 .................................................................................. F - 40
Main Components ............................................................................ F - 40
Oil Circulation Schematic ................................................................. F - 41
Power Flow - Forward Speeds ......................................................... F - 43
Power Flow - Reverse Speeds ......................................................... F - 45
Test points and connections ............................................................. F - 47
Electro-Hydraulic Shift Control ......................................................... F - 49
Dismantling and Assembly ............................................................... F - 51
Assembly .......................................................................................... F - 67
Hydraulic Control Unit - .................................................................... F - 97

Fault Finding
Functional Testing ................................................................................ F - 108
Semi - automatic ............................................................................ F - 109
Test Procedure (Automatic) ............................................................ F - 110
Transmission Fault Finding ................................................................. F - 113
Fault Codes (4WG-160/190/210) ........................................................ F - 120

Service Procedures
Electronic Monitoring System (EMS) Display Panel ............................ F - 140

Removal and Replacement

Replacement ....................................................................................... F - 141
Replacement of Loader Arm Control Transmission Dump
and Kickdown Switches .................................................................. F - 141
Replacement of Wiring to Kick down and Transmission
Dump Switches .............................................................................. F - 141
Removal and Replacement of Control Lever ................................. F - 142

Propshafts
Basic Operation ................................................................................... F - 143
Removing and Replacing ............................................................... F - 143

Axles
Front Axle ............................................................................................ F - 144
Removal ......................................................................................... F - 144
Replacement .................................................................................. F - 144

F-i F-i
 Section F - Transmission
Contents

Contents Page No.

Rear Axle ............................................................................................. F - 145
Removal ......................................................................................... F - 145
Replacement .................................................................................. F - 145
Rear Axle - Heavy Duty ....................................................................... F - 147
Removal ......................................................................................... F - 147
Replacement .................................................................................. F - 148
Hub and Driveshaft .............................................................................. F - 151
Dismantling ..................................................................................... F - 152
Assembly ........................................................................................ F - 153
Drive Head ........................................................................................... F - 156
Dismantling ..................................................................................... F - 157
Overhauling Pinion Bearing Support .............................................. F - 157
Pinion Depth ................................................................................... F - 158
Assembly ........................................................................................ F - 161
Crown Wheel and Pinion ..................................................................... F - 163
Adjustment ..................................................................................... F - 163
Correct Pattern ............................................................................... F - 163
Incorrect Pattern - High Contact ..................................................... F - 163
Incorrect Pattern - Low Contact ...................................................... F - 164
Limited Slip Differential Unit ................................................................ F - 165
Dismantling ..................................................................................... F - 166
Assembly ........................................................................................ F - 166

F - ii F - ii
 Section F - Transmission

Technical Data
426 and 436

Drive Axle - Front & Rear

426 & 436 436 (From Ser. No. 533692)

Type Type
Crownwheel & Pinion Ratio 3.909:1 Crownwheel & Pinion Ratio 4.083:1
Hub Ratio 5.167:1 Hub Ratio 5.167:1
Overall Axle Ratio 20.197:1 Overall Axle Ratio 21.098:1

Tyre Sizes and Pressures 436 (1)

426 (To Ser. No. 531762)

Standard

(1) Also 426 machines (USA ONLY) built after November 1998.

Front
17.5 - 25 16 ply 2.75 bar (40 lbf/in2) 20.5 - 25 12 ply 2.75 bar (40 lbf/in2)
17.5 R25 - 3.75 bar (54 lbf/in2) 20.5 R25 - 3.00 bar (44 lbf/in2)
555/70R25 - 3.50 bar (51 lbf/in2)

Rear
17.5 - 25 16 ply 1.75 bar (25 lbf/in2) 20.5 - 25 12 ply 1.75 bar (25 lbf/in2)
17.5 R25 - 2
1.75 bar (25 lbf/in ) 20.5 R25 - 1.50 bar (22 lbf/in2)
555/70R25 - 2.00 bar (29 lbf/in2)

Optional

Front
20.5 - 25 12 ply 2.0 bar (29 lbf/in2)
20.5 R25 - 2.0 bar (29 lbf/in2)

Rear
20.5 - 25 12 ply 1.75 bar (25 lbf/in2)
20.5 R25 - 1.75 bar (25 lbf/in2)

F-1 9803/4160-12 F-1

 Section F - Transmission
Technical Data
426 and 436
426 From Serial No. 532100

Table 1. Tyre Sizes and Pressures

FRONT REAR
Model Size Ply Bar lbf/in 2 Bar lbf/in2
426 17.5 - 25 16 2.75 40 1.75 25
426 17.5R25 - 3.75 55 1.75 25
426 20.5 - 25 12 2.50 36 1.75 25
426 20.5 R25 - 2.50 36 1.75 25
426 555/70R25 - 3.25 47 1.75 25

Note: If the tyres fitted to your machine are not listed, then
contact your JCB Distributor for advice, DO NOT guess
tyre pressures.

F-2 9803/4160-12 F-2

 Section F - Transmission
Technical Data
426 and 436

Transmission

426 436 446

Model WG-150 WG-200 WG-200
Torque Converter 300mm (11in) 300mm (11in) 340 (13in)
Dia.
Torque 2.91:1 2.66:1 2.879:1
Multiplication at
Stall

Forward Reverse Forward Reverse Forward Reverse

Gear Ratios 1st 4.222:1 1st 4.222:1 1st 4.278:1 1st 4.278:1 1st 4.278:1 1st 4.278:1
2nd 2.296:1 2nd 2.296:1 2nd 2.368:1 2nd 2.368:1 2nd 2.368:1 2nd 2.368:1
3rd 0.984:1 3rd 0.984:1 3rd 1.126:1 3rd 1.126:1 3rd 1.126:1 3rd 1.126:1
4th 0.629:1 Not Applicable 4th 0.648:1 Not Applicable 4th 0.648:1 Not Applicable

Oil Temperature 82 to 93°C (180 to 200°F) 82 to 93°C (180 to 200°F) 82 to 93°C (180 to 200°F)

426 (From Ser. No. 532100) 436 (From Ser. No. 533692)
Model WG-160 WG-190
Torque Converter 300mm (11in) 340mm (13in)
Dia.
Torque 2.549:1 2.873:1
Multiplication at
Stall

Forward Reverse Forward Reverse

Gear Ratios 1st 4.012:1 1st 3.424:1 1st 3.745:1 1st 3.551:1
2nd 2.024:1 2nd 1.919:1 2nd 2.089:1 2nd 1.981:1
3rd 1.088:1 3rd 1.031:1 3rd 1.072:1 3rd 1.017:1
4th 0.619:1 Not Applicable 4th 0.636:1 Not Applicable

Oil Temperature 82 to 93°C (180 to 200°F) 82 to 93°C (180 to 200°F)

F-3 9803/4160-12 F-3

 Section F - Transmission
Technical Data
426 and 436
Stall Testing brake. Select Forward Drive, keep brake pedal pushed
down, push the accelerator pedal down fully and record
Note: Switch off transmission dump (transmission the engine speed.
disconnect); the switch on the cab roof panel should not be
illuminated. Engage the parking brake and apply the foot
426 436 446
Maximum engine speed (rev/min) at:    2184

426  436 (From Ser. No. 533692)
2207 2146

WG - 160 (426) WG - 190 (436)

Pump Flow @ 2000 r.p.m. 80 l (17.6 UK gal, 21 US gal) 105 l (23 UK gal, 28 US gal)

System pressure 16+2 bar (232+29lb/in2) 16+2 bar (232+29lb/in2)

Torque converter
- input pressure (max) 9 bar (130 lb/in2) 9 bar (130 lb/in2)
-output pressure (max) 3.5 bar (51 lb/in2) 3.5 bar (51 lb/in2)
-output temperature (max)
-continuous 100°C (212°F) 100°C (212°F)
-short duration 120°C (248°F) 120°C (248°F)

Inductive transmitters (engine, turbine, central Geartrain

Resistance @ 20°C (68°F) 1050 ±105 ohms 1050 ±105 ohms
Temperature range -40°C (-40°F) - 150°C (302°F) -40°C (-40°F) - 150°C (302°F)
Torque limit - securing bolts 30Nm (22lbf ft, 3 kgf m) 30Nm (22lbf ft, 3 kgf m)

Speed sensor output

Temperature range -40°C (-40°F) - 150°C (302°F) -40°C (-40°F) - 150°C (302°F)
Working range 2Hz - 5kHz 2Hz - 5kHz
Supply voltage 24V 24V

Proportional valves in control valve

Resistance @ 20°C (68°F) 19 ±1.9 ohms. 19 ±1.9 ohms.
Current (mA) 100 - 500 100 - 500
Pressure range 2
0.8 - 8.3 bar (11.6 - 120lb/in ) 0.8 - 8.3 bar (11.6 - 120lb/in2)

Stall data
Engine idle 780 ±20 r.p.m. 850 ±10 r.p.m.

F-4 9803/4160-12 F-4

 Section F - Transmission
Technical Data
426 and 436

WG - 160 (426) WG - 190 (436)

Engine max no-load 2340±20 r.p.m. 2340±20 r.p.m.
Transmission 2200 r.p.m. 2200 r.p.m.
Hydraulic 2330 r.p.m. 2330 r.p.m.
Combined - transmission/hydraulic 2180 r.p.m. 2180 r.p.m.

F-5 9803/4160-12 F-5

 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Powershift Transmission
WG 150, WG 200

Control Valve
Removal

Fig 1. ( F-7). Separate control valve block and

channel plate from gear case.

1 Remove delivery line and plug open connections.

2 Remove socket head screws 1 securing the control

valve assembly.

Note: The screws are of several different lengths. Mark

them for correct positioning on reassembly.

3 Use two M8 adjusting screws to release the control

valve assembly and remove it.

4 Remove gaskets 2, 4 and intermediate plate 3.

5 Remove socket head screws 5 (11 off). Note the

positions of these screws for reassembly. Separate
channel plate 6, gaskets 7, 9 and intermediate plate 8
from gear case.

6 Place the control valve block on a clean, level work

surface if dismantling is required. See
Dismantle ( F-9).

F-6 9803/4160-12 F-6

 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 1. Control Valve

F-7 9803/4160-12 F-7

 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Refitting

Fig 1. ( F-7). Refitting control valve block and channel

plate to gear case.

1 Insert two headless M8 screws in the positions X in

the gearbox housing. Assemble gasket 9,
intermediate plate 8 and gasket 7 on these screws.

2 Fit channel plate 6 and secure with flat washers and

socket head screws 5 (11 off) in the arrowed
positions, replacing the headless screws with socket
head screws.

Note: The screws are M8 X 35 low headed screws.

3 Fit gaskets 4, intermediate plate 3 and gasket 2.

4 Attach the control valve assembly and secure with flat

washers and socket head screws 1 (8 off M8 X 65, 11
off M8 X 35 and 1 off M8 X 60).

Torque screws to 20Nm (15 lbf ft).

5 Refit delivery line.

F-8 9803/4160-12 F-8

 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Dismantle

Fig 2. ( F-10). Dismantle control valve block as

detailed below. The numerical sequence is a guide to the
order of dismantling.

1 Relax spring clip 1 and remove cover 2 and seal 3.

2 Pull off cable shoes, loosen socket head screws 4

and remove cable harness 6.

3 Remove socket head screws 7, retaining plates 9 and

washers 8. Remove solenoid valves 10 (5 off).

Note: Pay attention to the radial installation position of the

solenoid valves. Mark to ensure correct positioning on
assembly.

4 Remove pistons, compression springs, reduction

valve and other components 11 to 21 from left hand
side of control valve block.

5 Remove the end two socket head screws 22 and

replace with two M6 screws and nuts. Remove
remaining socket head screws and separate the shift-
control housing 23 and its gasket 24 from the valve
block using M6 adjusting screws.

Note: The shift-control housing is spring loaded.

6 Remove spools, compression springs and shim rings,

components 25 to 36 from right hand side of control
valve block.

7 Remove stop plate 37 and remove spool 39 together

with spring 38.

8 Dismantle pressure control valve, components 40 to

53.

9 Remove orifice and check valves, components 54 to

62.

F-9 9803/4160-12 F-9

 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 2. Control Valve Components

F - 10 9803/4160-12 F - 10
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Assemble Note: Pay attention to the correct positioning and
orientation of the spools.
Fig 2. ( F-10). Assemble the control valve block as
detailed below. 3 Pre-assemble 2-stage pressure control valve.

Key to abbreviations Close the bores with Ø 4.5mm ball bearings 63 (5 off).

Install the following components into the shift-control

Lo Free length of spring.
housing 23:
s Thickness.
a Spool 49, shim ring (if fitted) 48, spring 47 (Lo
Check all components for damage and renew if necessary. 70.9mm) and screw plug 45 with new O-ring 46.

Before commencing the installation, check the free b Cylindrical roller 44 (6 x 32 mm), shim ring(s) 43,
movement of the moving parts in the housing. spool 42 and screw plug 40 with new O-ring 41.

Spools may be renewed individually. c Spring 53 (Lo 34.9mm), spool 52 and screw plug
50 with new O-ring 51.
Lubricate all components before assembly.
Note: Pay attention to the installation position of spool 42,
Use new O-rings for all screw plugs. bore is facing the screw plug.

Shim rings fitted to the spools control the various operating 4 Install two M6 screws and nuts in place of the end two
pressures within the control valve. They may differ in socket head screws and position gasket 24.
number from those shown on the illustration.
Pull pre-assembled pressure control valve together
1 Install the check valves and orifice, components 54 to by means of nuts against shoulder and fasten it
62. To make assembly easier, fasten O-ring to the end subsequently by means of flat washers and socket
of the orifice with grease. head screws 22.

Torque screw plugs 54 to 35Nm (26 lbf ft). Torque screws 22 to 9.5Nm (7 lbf ft).

Torque screwplug 61 and orifice 58 to 20Nm (15 lbf 5 Into the left hand side of control valve block, introduce
ft). spool 39, spring 38 (Lo 51.3mm), preload and fix
them by means of stop plate 37.
Close the bores with Ø 4.5mm ball bearings 11 (10
off). 6 Install the following components:

2 Install the following components into the right hand a Spring 13 (Lo 51.3mm), control spool 12 (total
side of control valve block: length 39.5mm)

a Spring 36 (Lo 96.2mm), shim rings 35 and spool b Spring 15 (Lo 51.3mm), control spool 14
34.
c Reducing valve spool 21, spring 20 (Lo 37.1mm)
b Control spool 33, spring 32 (Lo 124.1mm), spring
31 (Lo 77.1mm), displacement spool 30. d Retaining plate 19, socket head screws 18

c Reversing spool 29, shim ring(s) 28, spring 27 (Lo e Spring 17 (Lo 51.3mm), pilot spool 16 (total length
56.3mm) 52.5mm).

d Control spool 26 (total length 55.5mm), Spring 25 7 Insert the solenoid valves 10 and fix them by means
of washers 8, retaining plates 9 and socket head

F - 11 9803/4160-12 F - 11
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
screws 7 (5 off each). Torque screws to 5.5Nm (4 lbf
ft).

Note: Pay attention to the radial installation position of the

solenoid valves. Also, ensure that the washer goes
between the valve body and the retaining plate.

8 Using new gasket, install complete cable harness 6

using socket head screws 4 and fixing plate 5.

9 Connect solenoid valves. Insert new seal 3 and fix the

cover 2 by means of the spring clip 1.

F - 12 9803/4160-12 F - 12
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Charge Pump
Dismantle

Fig 10. ( F-17). The following instructions assume the

gearbox is removed from the machine and clamped
securely on a suitable work surface, input drive uppermost,
as shown at 3-A.

1 Loosen hollow screws and remove delivery line 3-B.

2 Remove hex. head screws 3-C and separate engine

connecting case from gear case by means of pry
bars.

3 Loosen hollow screws and remove delivery line 3-D.

Fig 4.
4 Loosen hex. head screws 3-E, tap loose and remove
6 Remove hex. head screws 21 and separate pump
bearing cap 3-F.
from oil supply flange.

7 Remove rectangular section ring 18 and circlip 17.

Press output shaft 11 out of pump case.

8 If it is necessary to dismantle the pump, carry out the

procedure below, otherwise continue from Step 9.

a Remove the two straight pins using a slide

hammer. Remove the hex head screws and
remove cover.

b Examine the pump rotor gears, housing and cover

for wear. If the housing or cover shows signs of
wear, the complete pump must be replaced.

c Install the rotor set, fix the cover loosely by means

Fig 3. of the hex. head screws and insert the straight
pins (with the tapped hole showing upwards) until
5 Fasten a puller 4-G at the oil supply flange using hex. contact is made.
head screws. Pull the pump out of the housing bore.
d Fix the straight pins axially by means of caulkings
and tighten hex. head screws.

9 Remove converter relief valve (ball and spring)

shown at 5-H.

F - 13 9803/4160-12 F - 13
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Assemble

Fig 10. ( F-17). Assemble the charge pump as

detailed below.

1 Assemble converter control valve components

comprising washer 6-K, spring 6-L, spool 6-M and
valve sleeve 6-N. Fit temperature connection at 6-T,
ensuring that it engages in slot in valve sleeve 6-N. Fit
screw plug 6-P with a new O-ring.

2 Assemble drive shaft and oil supply flange.

a Fit rectangular section ring 1 to drive shaft 2.

Insert roll pins 3 and 4.

b Press roller bearing 5 against shoulder of oil

supply flange 6. Thread assembled drive shaft
through bearing. Position spur gear 7 with the
Fig 5.
long hub side away from roller bearing 5.
10 Squeeze out circlip 9 and press drive shaft 2 in the
c Press ball bearing 8 against shoulder of oil supply
direction of arrow X until spur gear 7 is released.
flange and secure with circlip 9.
Remove shim 20 and spur gear.
3 Assemble output shaft and change pump.
11 Remove ball bearing 8 and drive shaft. Using an
internal puller, pull roller bearing 5 out of the bore.
a Fit circlip 10 to output shaft 11. Press on ball
bearing 12 against the circlip.
12 Remove temperature connection from the gear case
at T. Remove screw plug 6-P and remove converter
Note: Ensure that the closed side of the bearing is against
control valve components shown at 6-J, comprising
the circlip.
washer 6-K, spring 6-L, spool 6-M and valve sleeve.
b Insert fitting key 13 into output shaft. Position shim
14 (nominal s = 0.8mm) and thread assembled
shaft through pump 15. Press the output shaft
against the shoulder of the pump.

c Press bearing 16 against the other side of the

pump, ensuring that the closed side of the bearing
is away from the pump.

d Squeeze in circlip 17. Check end play 0.2mm to

0.4mm between circlip and bearing inner race,
using feeler gauge. If outside these limits, correct
Fig 6. by means of shim 14.

e Using a plastic faced hammer, relax the output

shaft bearing by tapping. Squeeze in rectangular
section ring 18 and align it concentrically on the
shaft using grease.

4 Adjust the end play of the drive shaft bearing. This

must be 0.2mm to 0.4mm.

F - 14 9803/4160-12 F - 14
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
a Measure Dimension (i) from the pump flange c Calculate shim required:
mounted surface to the ball bearing contact area.
Dimension (i) = 7.10mm
e.g. Dimension (i) = 7.10mm
Dimension (ii) = -6.05mm

Difference = 1.05mm

Median end play = -0.30mm

Shim required = 0.75mm

5 Place the shim 20 in position on the pump face. Use

grease to adhere it.

6 Assemble the charge pump to the oil supply flange.

a Install two headless M8 screws in the outer pump

securing screw positions, place flat gasket 19 in
position and insert converter relief valve (ball and
spring) into oil supply flange.

b Using the headless screws as a guide, place

pump against oil supply flange, securing it with
hex. head screws 21, removing the headless
screws.
Fig 7.
c Relax the output shaft bearing by tapping and
b Fit gasket 19 and measure Dimension (ii) from the check the free movement of the spur gear.
end face/ball bearing to the gasket (flange
mounted surface). 7 Fit the pump/flange assembly to the gear case.
e.g. Dimension (ii) = 6.05mm a Heat housing bore using a hot air blower.

b Install two headless M8 screws in two

diametrically opposite securing screw positions
and place flat gasket 22 in position.

c Using the headless screws as a guide, place

pump/ flange assembly in position.

8 Assemble needle bearing 23 and shaft seal 24 into

bearing cover 25. Wet shaft seal outer diameter with
sealing compound. Position flat gasket 26, fit
rectangular ring 28 and secure assembled bearing
cover using M8 screws 27, removing the headless
screws. Torque screws to 23Nm (17 lbf ft).

9 Fasten engine connecting case using M10 hex. head

screws 9-X. Torque screws to 68Nm (50 lbf ft).

Fig 8. 10 Refit oil lines 9-Y and 9-Z, using new sealing rings.

F - 15 9803/4160-12 F - 15
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 9.

F - 16 9803/4160-12 F - 16
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 10. Charge Pump

F - 17 9803/4160-12 F - 17
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Coaxial Power Take-off

Dismantle

Fig 11. ( F-19). Dismantle the coaxial power take-off

as detailed below.

1 Remove hex. head screws 5 and, using a set of eye

bolts, lift complete power take-off housing out of the
bore.

2 Fasten power take-off in a vice. Expand two snap

rings 8, align them centrally and, using a soft faced
hammer, tap the drive dog about 5 to 10mm forwards.

Note: An assistant is necessary for this step.

3 Squeeze out snap ring 13, tap the drive dog loose and
drive it out of the spur gear.

Note: Pay attention to the released components.

F - 18 9803/4160-12 F - 18
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 11. Coaxial Power Take-off

F - 19 9803/4160-12 F - 19
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Assemble 7 Insert stud 13-11 (if previously removed) into face of
gearbox as shown at 13-C, using JCB Lock and Seal,
Fig 11. ( F-19). Assemble the coaxial power take-off fit two headless M8 screws into diametrically opposite
as detailed below. holes in the gear case and lay on the gasket 3.

1 Install snap rings 1 and needle bush 2 into housing 4.

Note: The needle bush is marked on one end face. When

pressing in the bush, the marking must be facing outwards.

2 Squeeze the two snap rings 8 into the annular groove

at the front of the housing.

3 Assemble drive dog 6 and roller bearing 7, secure

them using circlip 9.

Note: Ensure that the annular groove A is on the outer side

of the bearing.

4 Position spur gear 14 and snap ring 13, push the drive
dog into the housing until the snap ring is located on Fig 13.
the drive dog.
8 Install pre-assembled power take off and secure
5 Expand the two snap rings 8, position them as shown using hex. head screws 5 (10 off), replacing the
at 12-B and tap drive dog into housing until the first headless screws with hex. head screws, and a hex.
snap ring engages in the annular groove of the roller nut 12 on stud 11. Torque screws 5 and nut 12 to
bearing. 23Nm (17 lbf ft).

Fig 12.

6 Locate snap ring 13 finally, thus securing the spur

gear. Relax the bearing by tapping with a soft face
hammer.

F - 20 9803/4160-12 F - 20
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Lateral Power Take-off

Dismantle

Fig 14. ( F-22). Dismantle the lateral power take-off

as detailed below.

1 Remove hex. head screws 13 and remove pump

flange 12.

2 Squeeze out circlip 5 from the housing interior.

3 Using an internal puller, pull drive dog out of ball

bearing and spur gear. Remove spur gear.

4 Expand snap rings 6, align them concentrically and,

using a soft faced hammer, tap the ball bearing 7 out
of the housing bore.

Note: An assistant is necessary for this step.

F - 21 9803/4160-12 F - 21
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 14. Lateral Power Take-off

F - 22 9803/4160-12 F - 22
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Assemble

Fig 14. ( F-22). Assemble the lateral power take-off

as detailed below.

1 Squeeze snap rings 6 into the groove of the lower

housing bore.

2 Lay expanding ring 15-S on the snap rings and mount

ball bearing 15-7, with the recess showing upwards.
Tap the ball bearing in, until the upper snap ring
engages in the ball bearing groove.

Fig 16.

6 Press needle bush 14 into pump flange 12 and secure

using snap ring 15.

7 Install two headless M8 screws in two diametrically

opposite securing screw positions and place flat
gasket 11 in position. Using the headless screws as a
guide, place pump flange assembly in position.
Secure pump flange using M8 screws 13, replacing
the headless screws with hex. head screws. Torque
screws to 16Nm (12 lbf ft).
Fig 15.
8 If removed, install the power take-off oil supply, items
3 Position spur gear 8 with the longer hub side 1 to 4, using new sealing rings.
downwards.

4 Squeeze snap ring 10 into the annular groove A of the

driving shaft 9.

5 Heat ball bearing and introduce driving shaft until

contact is made. Secure shaft using circlip 16-5.

F - 23 9803/4160-12 F - 23
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Layshaft Replacing

Removing Fig 17. ( F-25). Insert the roller bearing 6 into the spur
gear 5 and install the assembled spur gear and shim 7.
Fig 17. ( F-25). Remove cover 1 over layshaft and
remove socket head screw 2. Note: The layshaft gear is marked on the end face. This
marking should face the drive side C.
Using Special Tool 892/00224 and a suitable threaded bar,
pull axle 4 out of the spur gear 5 and remove from the gear Heat bearing bores and bearing inner race to about 90°C
case. using a hot air blower.

Remove the spur gear, roller bearing 6 and shim 7. Fit a new O-ring 3, positioned at B and insert axle 4 until
fully home. Secure using socket head screw 2. Use JCB
Lock and Seal and torque screw to 80Nm (59 lbf ft).

Replace cover.

F - 24 9803/4160-12 F - 24
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 17. Layshaft

F - 25 9803/4160-12 F - 25
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Final Drive
Dismantle

Fig 19. ( F-27). Dismantle the final drive as detailed

below.

1 Remove lock plate 27 and hex. head screws 28. Pry

output flange 23 off the shaft.

2 Turn the gear case over and repeat for items 15 to 21.

3 Pry shaft seal 14 out of the housing bore, squeeze out

circlip 13 and remove shim 12.

4 Remove closing covers 18-A, remove two hex. head

screws 29 and washers 30 and take out oil retainer 7.

Fig 18.

5 Drive output shaft 9 out of output gear 6 and remove

it. Remove output gear and plate 4.

6 Turn the gear case over, pry shaft seal 22 out of the
housing bore, squeeze out circlip 1 and remove shim
2.

F - 26 9803/4160-12 F - 26
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 19. Final Drive Components

F - 27 9803/4160-12 F - 27
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Assemble

For steps 1 to 5, Fig 20. ( F-28). For all other steps

Fig 19. ( F-27).

Fig 20.

1 Squeeze in circlip 20-1. Turn gear case over and lay b Measure Dimension (ii) from the end face of the
shim 20-2 and roller bearing 20-3 upon circlip 20-1. output shaft to the upper plane surface of the
circlip.
2 Introduce plate 20-4 through the large housing bore
and lay it over roller bearing 20-3. e.g. Dimension (ii) = 79.10mm

3 Heat inner bearing race 20-5 and assemble it on to c Calculate end play.
spur gear 6. Position spur gear 20-6.
e.g. Dimension (i) = 79.50mm
4 Position oil retainer 20-7 and fasten together with
plate 20-4 using hex. head screws 20-29 and flat Dimension (ii) = -79.10mm
washers 20-30. Apply JCB Lock and Seal to screws
and torque to 23Nm (17 lbf ft). End play = 0.40mm

5 Squeeze in circlip 20-8. If the end play is outside the tolerance allowed,
correct by means of a corresponding shim 2.
6 Press spacer 10 against shoulder of output shaft 9.
Thread output shaft through the assembly until 8 Remove the output shaft and press ball bearing 11
contact is made. against shoulder. Heat the housing bore and thread
the output shaft into the assembly until contact is
7 Check end play of the output shaft bearing. It must be made. Secure ball bearing free of play using shim 12
0.3mm to 0.5mm. and circlip 13.

a Measure Dimension (i) from the end face of the 9 Grease the lip of shaft seal 14 and insert with the
output shaft to the contact face of the ball bearing. sealing lip facing the oil chamber.

e.g. Dimension (i) = 79.50mm

F - 28 9803/4160-12 F - 28
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Note: If the outer diameter of shaft seal is rubberised, wet
the sealing surface with spirit. If not, use sealing
compound.

10 Refit the two closing covers.

11 Insert hex. head screws 15 in the bores of output

flange 16. Heat the flange and press into position. Fit
new O-ring 17, spacing washer 18 and secure using
washer 19, lock plate 20 and hex. head screws 21.
Torque screws to 46Nm (34 lbf ft).

Note: Wet the contact surface of washer and screws with

sealing compound.

12 Turn the gear case over and assemble items 22 to 28

in a similar manner.

F - 29 9803/4160-12 F - 29
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Multi-Disc Clutches
Fig 21. ( F-31)

Removing

1 Loosen hex. nuts 41 and, using a suitable puller, draw

the axle 39 out of clutch K4/K3 and out of the gear
case.

Note: Studs 42 remain attached to gearcase, remove

these only if damaged.

2 Push the lower spacing washer to the rear and lift

clutch assembly K4/K3 from the gear case.

3 Remove clutches KR/K2 and KV/K1 in a similar

manner.

Dismantling

Note: Clutch K4/K3 is shown, clutches KR/K2 and KV/K1

are dismantled in a similar manner.

1 Remove spur gear K3, item 31, and demount

components 30 to 34.

2 Squeeze out snap ring 29 and remove plate pack K3,

item 27.

3 Compress spring 16, squeeze out v-ring 19 and

remove components 15 to 19.

4 Remove piston 14.

5 Pull needle bush 11 out of the bore, using an internal

puller.

6 Turn over plate carrier and remove components 2 to

25 and 35 to 37.

F - 30 9803/4160-12 F - 30
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 21. Multi-Disc Clutches

F - 31 9803/4160-12 F - 31
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Clutch K4/K3 Note: Plate pack K4 comprises:

Fig 21. ( F-31) 9 outer plates a, s = 2.0mm

Note: On later transmissions, 4 inner plates b, s = 1.5mm

1 Needle bushes 2 and 11 are secured into disc carrier 2 inner plates c, s = 2.0mm
1 by circlips.
1 inner plate d, s = 2.5mm
2 Item 34 is modified, ie. not the same as 26.
1 compensating plate e, s = 1.5, 2.0 or 2.5mm
3 A shim is fitted between items 30 and 31.
Assemble pack as shown, starting with one outer
Assembling plate a, finishing with compensating plate e and a final
outer plate a.
Fig 21. ( F-31).
3 Install plate pack K4, fit backing plate 21 and secure
1 Pre-assemble plate carrier K4/K3, item 1. plate pack using snap ring 22.

a Press needle bush 2 carefully against shoulder. 4 Check plate clearance (piston travel) of plate pack
K4.
Note: The needle bush is marked on one end face. This
must be facing outwards. a Measure dimension (i) from the end face of the
plate carrier to backing plate.
b Check operation of bleeder valves. If necessary,
clean by use of compressed air. e.g. Dimension (i) = 5.3mm

c Lubricate and insert the profiled sealing rings 3, b Lift backing plate until in contact with snap ring
and 4 in the recesses of the piston 5, with the and re-measure to obtain dimension (ii).
sealing lip in each case facing the pressure
chamber. e.g. Dimension (ii) = 3.2mm

d Insert the piston into the plate carrier, pushing all c Subtract dimension (ii) from dimension (i) to
the way down. obtain plate clearance. This must be between
2.0mm and 2.4mm
e Assemble lower spring guide 6, compression
spring 7 and upper spring guide 8. Plate clearance = 5.3 - 3.2 = 2.1mm

f Mount guide ring 9 and v-ring 10, preload 5 Install spur gear K4, items 23 to 25, replace thrust
compression spring and secure using v-ring. plate 26 and insert assembled spur gear into plate
carrier, ensuring all the inner plates mate with the
g Repeat for items 11 to 19 on the other side of the spur gear.
plate carrier.
6 Assemble plate pack K3, items 27a to 27e as shown,
2 Make up plate pack K4, items 20a to 20e. install into plate carrier using backing plate 28 and
snap ring 29. Check plate clearance as described for
clutch K4.

F - 32 9803/4160-12 F - 32
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
Note: Plate pack K3 comprises: b Measure as shown at 23-B along the axle from
the face which butts against the bearing rollers to
10 outer plates a, s = 2.0mm obtain dimension (ii).

6 inner plates b, s = 2.0mm e.g. Dimension (ii) = 21.00mm

1 inner plates c, s = 1.5mm

1 inner plate d, s = 2.5mm

1 compensating plate e, s = 1.5, 2.0 or 2.5mm

7 Assemble spur gear K3, items 30 to 33, using grease

to hold thrust washer 30 and rollers 33.

Note: Exchange cylindrical rollers 33 in sets only.

8 Replace thrust plate 34 and insert assembled spur

gear into plate carrier, ensuring all the inner plates
mate with the spur gear.

9 Adjust the end play of clutch K4/K3. This must be

between 0.1mm and 0.3mm.

a Lay forked washer 36 and thrust washer 35 in

position in the gear case and measure dimension
(i) from the surface of the axle mounting flange to
thrust washer as shown at 22-A. Remove forked
washer and thrust washer.

e.g. Dimension (i) = 251.15mm Fig 23.

c Place clutch on a suitable surface plate and

measure as shown at 24-C from the end/face
cylindrical rollers to the surface plate to obtain
dimension (iii).

e.g. Dimension (iii) = 227.20mm

Fig 22.

F - 33 9803/4160-12 F - 33
 Section F - Transmission
Powershift Transmission
WG 150, WG 200
14 Check the operation of clutches K4 and K3 using
compressed air. The opening and closing of the
clutches should be clearly audible.

Fig 24.

d Add the median end play (0.20mm) to dimension

(iii) to obtain the installation dimension.

e.g 227.20 + 0.20 = 227.40mm

e Subtract dimension (ii) from dimension (i) to

obtain the housing dimension.

e.g 251.15 - 21.00 = 230.15mm

f Subtract the installation dimension from the

housing dimension to calculate shim required.

e.g 230.15 - 227.40 = 2.75mm

10 Install clutch K4/K3 into gear housing. Fit thrust

washer 35, forked washer 36 and calculated shim 37.

11 Fit rectangular section rings 38 to axle 39. Ensure

they are aligned concentrically. Lubricate and fit new
O-ring 40.

12 Heat housing bores using a hot air blower. Insert axle

into clutch K4/K3 until axle flange is in contact with
gear housing. Fit hex. nuts 41 and torque to 23Nm (17
lbf ft).

13 Recheck clutch end play and correct if necessary.

F - 34 9803/4160-12 F - 34
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Clutch KR/K2 10 Install clutch KR/K2 into gear housing. Fit washers
and shim, items 38 to 40.
Fig 25. ( F-36). The procedures for assembling
clutches KR/K2 and KV/K1 follow closely that given for 11 Before continuing further, clutch KV/K1 must be
clutch K4/K3. Detailed instructions will therefore be given installed, together with the lateral power take-off (if
only where significant differences exist. fitted).

Assembling 12 Assemble axle, items 41 to 43. Use new O-ring 43.

Note: On later transmissions, 13 Heat housing bores using a hot air blower. Insert axle
into clutch KR/K2 until axle flange is in contact with
1 Needle bushes 2 and 11 are secured into disc carrier gear housing. Fit hex. nuts 44 and torque to 23Nm (17
1 by circlips. lbf ft).

2 Item 34 is modified, ie. not the same as 26. 14 Recheck clutch end play and correct if necessary.

3 Assemble items 2 to 10 and 11 to 19 into plate carrier 15 Check the operation of clutches KR and K2 using
KR/K2, item 1. compressed air.

4 Make up plate pack KR, items 20a to 20d.

Note: Plate pack KR comprises:

12 outer plates a, s = 2.0mm

9 inner plates b, s = 2.0mm

1 inner plate c, s = 2.5mm

1 compensating plate d, s = 2.0 or 2.5mm

Assemble pack as shown, starting with one outer

plate a, finishing with compensating plate d and a
final outer plate a.

5 Install plate pack KR using backing plate 21 and ring

22 and check plate clearance (2.6mm to 3.0mm).

6 Install spur gear KR, items 23 to 29 into plate carrier.

7 Assemble plate pack K2, items 30a to 30d, install into

plate carrier using backing plate 31 and ring 32 and
check plate clearance (2.0mm to 2.4mm).

Note: Plate pack K2 comprises:

8 outer plates a, s = 2.0mm

4 inner plates b, s = 2.0mm

2 inner plates c, s = 2.5mm

1 compensating plate d, s = 2.0 or 2.5m

8 Assemble spur gear K2, items 33 to 37 into plate

carrier

9 Adjust the end play of clutch KR/K2. This must be

between 0.1mm and 0.3mm.

F - 35 9803/4160-12 F - 35
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 25. Clutch KR/K2

F - 36 9803/4160-12 F - 36
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Clutch KV/K1 9 Before continuing further, clutch KR/K2 must be

installed, together with the lateral power take-off (if
Fig 26. ( F-38). The procedures for assembling fitted).
clutches KR/K2 and KV/K1 follow closely that given for
clutch K4/K3. Detailed instructions will therefore be given 10 Assemble axle, items 45 to 47. Use new O-ring 47.
only where significant differences exist.
11 Heat housing bores using a hot air blower. Insert axle
Assembling into clutch KV/K1 until axle flange is in contact with
gear housing. Fit hex. nuts 48 and torque to 23Nm (17
lbf ft).
Note: On later transmissions,
a Needle bushes 2 and 11 are secured into disc 12 Recheck clutch end play and correct if necessary.
carrier 1 by circlips.
13 Check the operation of clutches KV and K1 using
b Item 34 is modified, ie. not the same as 26.
compressed air.

1 Assemble items 2 to 10 and 11 to 19 into plate carrier

KV/K1, item 1.

2 Make up plate pack KV, items 20a to 20d.

Note: Plate pack KV comprises:

12 outer plates a, s = 2.0mm

9 inner plates b, s = 2.0mm

1 inner plate c, s = 2.5mm

1 compensating plate d, s = 2.0 or 2.5mm

Assemble pack as shown, starting with one outer

plate a, finishing with compensating plate d and a
final outer plate a.

3 Install plate pack KV using backing plate 21 and ring

22 and check plate clearance (2.6mm to 3.0mm).

4 Install spur gear KV, items 23 to 29 into plate carrier.

5 Assemble plate pack K1, items 30a to 30d, install into

plate carrier using backing plate 31 and ring 32 and
check plate clearance (2.0mm to 2.4mm).

Note: Plate pack K1 comprises:

8 outer plates a, s = 2.0mm

4 inner plates b, s = 2.0mm

2 inner plates c, s = 2.5mm

1 compensating plate d, s = 2.0 or 2.5mm

6 Assemble spur gear K1, items 33 to 41 into plate

carrier

7 Adjust the end play of clutch KV/K1. This must be

between 0.1mm and 0.3mm.

8 Install clutch KV/K1 into gear housing. Fit washers

and shim, items 42 to 44.

F - 37 9803/4160-12 F - 37
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Fig 26. Clutch KV/K1

F - 38 9803/4160-12 F - 38
 Section F - Transmission
Powershift Transmission
WG 150, WG 200

Emergency Steering Pump Replacing

Removing Squeeze in circlip 4, assemble spur gear 3 until contact is

made and secure it free of play using shim 2 and circlip 1.
Remove hex. nuts 7 and gently prise emergency steering
pump from the gear case. Note the radial orientation of the Fit a new, lubricated O-ring 5 into the annular groove on
pump for reference when refitting. the pump case.

Note: If it is necessary to dismantle the emergency Insert studs 6 (4 off) into tapped holes in gear case,
steering pump further, see Section H - Steering - securing with JCB Lock and seal. Assemble emergency
Emergency Steering Pump. steering pump onto the studs and secure with hex. nuts 7.
Torque nuts to 23Nm (17 lbf ft).

Note: Pay attention to the radial orientation of the pump.

Fig 27.

F - 39 9803/4160-12 F - 39
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

WG 160, WG 190

Main Components

Fig 28.
Key
1 Input drive plate
2 Torque converter
3 Converter bell housing
4 Breather
5 Cover - transmission case
6 Filter head
7 Filter
8 Parking brake caliper
9 Output drive flange/brake disc to front axle
10 Magnetic oil drain plug
11 Output drive flange to rear axle
12 Transmission case
13 Lifting lugs
14 Hydraulic pump mounting
15 Electro-hydraulic control unit

F - 40 9803/4160-12 F - 40
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Oil Circulation Schematic

F - 41 9803/4160-12 F - 41
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 42 9803/4160-12 F - 42
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Power Flow - Forward Speeds

Fig 30.

F - 43 9803/4160-12 F - 43
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Clutches Actuated

Fig 30. ( F-43)

Speed Clutches
1st Forward KV/K1
2nd Forward KV/K2
3rd Forward KV/K3
4th Forward K3/K4

Key
KV Clutch forward
KR Clutch reverse
K1 Clutch 1st speed
K2 Clutch 2nd speed
K3 Clutch 3rd speed
K4 Clutch 4th speed
IN Input
OU Output

F - 44 9803/4160-12 F - 44
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Power Flow - Reverse Speeds

Fig 31.

F - 45 9803/4160-12 F - 45
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Clutches Actuated

Fig 31. ( F-45)

Speed Clutches
1st Reverse KR/K1
2nd Reverse KR/K2
3rd Reverse KR/K3

Key
KV Clutch forward
KR Clutch reverse
K1 Clutch 1st speed
K2 Clutch 2nd speed
K3 Clutch 3rd speed
K4 Clutch 4th speed
IN Input
OU Output

F - 46 9803/4160-12 F - 46
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Test points and connections

Fig 32.

F - 47 9803/4160-12 F - 47
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 32. ( F-47)

Item Description Control unit valve block Port
Identification
Test points
29 Torque Converter Inlet Pressure H
30 Torque Converter Outlet Pressure -
31 Clutch - Forward (KV) Pressure B
32 Clutch - Reverse (KR) Pressure E
33 Clutch - 1st Speed(K1) Pressure D
34 Clutch - 2nd Speed (K2) Pressure A
35 Clutch - 3rd Speed (K3) Pressure C
36 Clutch - 4th Speed (K4) Pressure F
37 Torque Converter Outlet Temperature -
38 System Pressure K
39 Cooler Input Flow -
40 Cooler Output Flow -
Measuring Devices
41 Inductive Transmitter - turbine r.p.m -
42 Speed Sensor Output -
43 Inductive Transmitter - central geartrain r.p.m -
44 Inductive Transmitter - engine r.p.m -
Connections
45 Electrical connection to control unit -
46 Pilot pressure (optional) J
47 System pressure (optional) G

F - 48 9803/4160-12 F - 48
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Electro-Hydraulic Shift Control

 



 
 
 
 
 


Fig 33.

Note: View 33-B-B shows proportional valve 33-13.

Proportional vales 33-9to12 and 33-14 are functionally
identical.

F - 49 9803/4160-12 F - 49
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Key
V Valve block
W Housing
X Cover
Y Duct plate
Z Gasket

F - 50 9803/4160-12 F - 50
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Dismantling and Assembly 4 Remove lock plate 12 and the two screws 13.
Remove disc 14 and pry drive flange 15 off the shaft.
To facilitate the following procedures it is advisable to
support the transmission assembly in a suitable adjustable 5 Mark radial installation position of the housing cover
jig which allows the unit to be rotated as necessary. 11 and bell housing 26. Remove the screws 16 and
nuts 17.
Dismantling
6 Separate converter along with cover 11 from the bell
Fig 36. ( F-52). The numerical sequence is a guide to housing using lifting device.
the order of dismantling.
7 Press drive shaft torque converter out of the cover 11.
Separate Hydraulic Control Unit (HSG-90) and Duct
Plate from Gearbox 8 Remove circlip 19 and extract bearing 20 from cover
11.
1 Remove two socket head screws 1 (one top and one
bottom). Install threaded alignment dowels (M6) in 9 Remove the four screws 21 and separate diaphragm
their place to prevent hidden components falling out 22, complete with drive shaft 18, from torque
during dismantling. converter 23.

Remove the remaining socket head screws 1 and 10 Remove screws 24 and separate drive shaft 18 from
separate control unit 2 from duct plate 3. diaphragm 22.

Note: For dismantling and assembly of control unit 2, refer 11 Returning to the transmission assembly, remove the
to Hydraulic Control Unit - ( F-97), engine inductive transmitter arrowed. Fig
Dismantling ( F-97) and Assembly ( F-99). 35. ( F-51).

2 Remove gaskets 4 and 6 and intermediate plate 5.

Remove socket head screws 7 nuts 8 and washers 9.
Separate duct plate 3 from gearbox housing. Remove
gasket 10.

3 Pull the torque converter safety valve out of the

gearbox housing bore as shown in Fig
34. ( F-51).

Fig 35.

12 Remove screws 25 and separate the converter bell

housing 26 from the transmission assembly.

Note: Mark radial installation position of converter bell

housing 26 and the transmission housing.

Fig 34.

F - 51 9803/4160-12 F - 51
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 36. Hydraulic Control Unit and Torque Converter

F - 52 9803/4160-12 F - 52
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Hydraulic Pump

Fig 40. ( F-54).

1 Remove screws 1 securing the hydraulic pump

assembly 2, 3, 4 to the transmission housing.

2 Using a suitable separating device clamped to the

exposed portion of pump stator shaft 4 as shown in
Fig 37. ( F-53), pull pump carefully out of the
housing bore by means of two-leg puller.

Fig 38.

4 Remove socket head screws 5, 6 and 7 as well as the

two hexagonal screws 8. Remove oil feed housing -9
and gasket 10 from housing 11.

Converter Back Pressure Valve

1 Preload compression spring and remove lock plate B.

Remove released components C, D and E in Fig
39. ( F-53).
Fig 37.

3 Separate the pump, items 2 and 3 from stator shaft 4.

Separate control disc 3 from pump rotor 2.

If the original pump is to be refitted position control

disc 3 on top of rotor 2 and secure together using two
grooved pins A via the holes arrowed in Fig
38. ( F-53).

Fig 39.

2 Remove screws 12 and take off cover 13 and gasket

14.

F - 53 9803/4160-12 F - 53
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 40. Hydraulic Pump

F - 54 9803/4160-12 F - 54
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Remove Output Shaft, Input Shaft and Clutches

Fig 44. ( F-57).

1 Remove lock plate 1, screws 2 and retainer disc 3.

Remove seal 4 and pry torque converter-side drive
flange 5 off the shaft. Pry shaft seal 6 out of the
housing bore.

Repeat for the opposite drive flange assembly 7, 8, 9,

10, 11 and 12.
Fig 42.
2 Remove speed sensor F as well as both inductive
transmitters G. Fig 41. ( F-55). 6 To facilitate separation of the housing cover from the
transmission gearbox housing proceed as follows:

a Attach two M20 eyebolts H and one M16 eyebolt

J to the housing cover. Fig 43. ( F-55).

Lifting Eye (M20) 892/01015

Lifting Eye (M16) 892/01013

b Attach retainers K to the threaded studs

protruding through the housing cover from the six
clutches. As an alternative to the retainers, fit
washers and M10 nuts over each stud and tighten
firmly. Fig 43. ( F-55).

Retainer 892/01014

Fig 41.

3 Remove nuts 13 and washers 14. Remove cover 15

and seal 16.

Repeat for the second cover assembly 18, 19, 20 and

21.

4 Remove screw 23 connection (housing/housing

cover).

5 Drive out both cylindrical pins (see arrows in Fig

42. ( F-55)).

Fig 43.

7 Separate housing cover along with clutches from the

gearbox housing, using lifting device. Fasten housing
cover on the assembly jig.

F - 55 9803/4160-12 F - 55
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
8 Remove socket head screws 24 and remove output
shaft assembly 25, 26 and 27 as well as the two oil
collecting plates 28 and 29.

9 Pull off tapered roller bearing 26. Remove opposite

tapered roller bearing 27 accordingly. Separate oil
collecting plates 28 and 29 from output shaft 25.

Bearing Tool 892/01004

Bearing Puller 892/01003

F - 56 9803/4160-12 F - 56
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 44. Output and Input Shafts

F - 57 9803/4160-12 F - 57
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Important: For the following steps refer to Fig
45. ( F-59).

Rotate the torque converter half of the transmission

gearbox in the support jig so that the clutch
assemblies are uppermost.

AN = Input (drive) Shaft

KV = Clutch - Forward

KR = Clutch - Reverse

K1 = Clutch - 1st Speed

K2 = Clutch - 2nd Speed

K3 = Clutch - 3rd Speed

K4 = Clutch - 4th Speed

10 Remove the six clutch retainers fitted at step 6b.

Note: The following procedures to remove the clutch

packs require the participation of two people.

11 Lever clutch K4 upwards from its bearing seat and lift

out clutch K1. Relocate clutch K4 to its bearing seat.

12 Remove clutches K2 and K3 in turn.

13 Lift clutch KV and KR by means of pry bars and

remove clutch K4.

14 Lift clutch KV and clutch KR as well as input shaft AN

together out of the housing cover.

15 Remove the bearing outer races left behind in the

housing after clutch/shaft removal but only those for
individual bearings, if any, which are being renewed.

16 Tilt housing cover 90°.

17 Remove screws 1, retaining plate 2 and gasket 3.

18 Extract circlip 4 and separate pump shaft 5, ring 6 and

bearing 7 from housing cover.

19 Extract ring 6 and press bearing 7 from shaft 5.

F - 58 9803/4160-12 F - 58
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 45. Clutches and Pump Shaft

F - 59 9803/4160-12 F - 59
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 60 9803/4160-12 F - 60
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 61 9803/4160-12 F - 61
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 62 9803/4160-12 F - 62
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 63 9803/4160-12 F - 63
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 64 9803/4160-12 F - 64
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 65 9803/4160-12 F - 65
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 66 9803/4160-12 F - 66
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Assembly
Install Oil Tubes

Note: To ensure the correct installation of the oil tubes, the

use of one of the Special Tools is imperative.

1 Insert suction pipe 1, pressure pipes 2, 3 and

pressure lubrication pipe 4 into the housing bores.
Fasten suction and pressure pipes by means of
socket head screws (arrowed in Fig 50. ( F-67)).

Torque limit (M8/8)................ 23 Nm (17 lbf ft).

Fig 51.

Pipe Swaging Tool 892/01008

Pipe Swaging Tool 892/01007

Pipe Swaging Tool 892/01009

3 Insert O-rings (arrowed in Fig 52. ( F-67)) into

the annular grooves of the two oil tubes and oil them.

Fig 50.
Fig 52.
2 Tilt housing 180°.
4 Assemble both oil tubes A until contact is obtained.
Equip screw plug B with new O-ring and install it.
Note: The rolled pipe ends must not protrude beyond the
Fig 53. ( F-68).
level of the mating flange of the housing. If necessary
adjust individual pipes to suit.
Torque limit...................................140 Nm (103 lbf ft).
Roll the suction and pressure pipes into the housing
apertures arrowed in Fig 51. ( F-67), using
special tool.

F - 67 9803/4160-12 F - 67
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
2 Equip plugs E with new O-rings and install them.

Torque limit (M16 x 1.5).................... 40 Nm (30 lbf ft)

Torque limit (M18 x 1.5).................... 50 Nm (37 lbf ft)

Torque limit (M26 x 1.5).................... 80 Nm (59 lbf ft)

Fig 53.

5 Insert both oil tubes C into the housing cover. Tilt

housing cover 180° and roll oil tubes into the housing
bores.

Note: The rolled pipe ends must not protrude beyond the Fig 55.
level of the mating flange of the housing. If necessary
adjust individual pipes to suit. 3 Insert sealing cover F with the recess showing
upward.
If necessary equalise projection of the tube.
Note: Wet contact face with JCB Threadlocker and Sealer
(High Strength).

Fig 54.

Install Studs, Plugs and Sealing Cover

Fig 56.
1 Mount studs D (M8 x 25).

Torque limit (studs)......................9.0 Nm (6.6 lbf ft)

Note: Wet screw-in thread with JCB Threadlocker and

Sealer (High Strength)

F - 68 9803/4160-12 F - 68
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 69 9803/4160-12 F - 69
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 70 9803/4160-12 F - 70
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 71 9803/4160-12 F - 71
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 72 9803/4160-12 F - 72
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 73 9803/4160-12 F - 73
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 74 9803/4160-12 F - 74
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 75 9803/4160-12 F - 75
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

CAUTION

F - 76 9803/4160-12 F - 76
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

CAUTION

F - 77 9803/4160-12 F - 77
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 78 9803/4160-12 F - 78
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

CAUTION

F - 79 9803/4160-12 F - 79
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 80 9803/4160-12 F - 80
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 81 9803/4160-12 F - 81
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 82 9803/4160-12 F - 82
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 83 9803/4160-12 F - 83
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

F - 84 9803/4160-12 F - 84
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Install Pump Shaft 2 Grease rectangular ring 6, align it centrally and
introduce pump shaft 5 into the housing cover until
1 Install ball bearing 7. Fit rectangular ring 6 and let it contact is obtained.
snap in.
3 Fix pump shaft 5 by means of circlip 4. Fit gasket 3
and retaining plate 2 and secure with screws 1.

Fig 87.

F - 85 9803/4160-12 F - 85
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Install Oil Seal Covers 2 Fit output flange 11. Insert O-ring 10 into the gap
between drive flange and shaft.
1 Insert O-rings 16 and 21 into the annular groove of
the oil feed covers 15 and 20 respectively. 3 Secure output flange 11 by means of disc 9 and
screws 8.
2 Fasten covers 15 and 20 by means of nuts/plain
washers 13/14 and 18/19 respectively. Torque limit........................ 46 Nm (34 lbf ft).

Torque limit...................... 23 Nm (17 lbf ft). 4 Secure screws by means of lock plate 7.

Install Output Flanges 5 Repeat steps 1 - 4 for the opposite drive flange
assembly 1,2, 3, 4, 5 and 6.
1 Install shaft seal 12 with the sealing lip facing the oil
chamber.

Wet rubber coated outer diameter with spirit. Grease

sealing lip.

Fig 88.

F - 86 9803/4160-12 F - 86
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Installation - Converter Back Pressure Valve

Fig 89. ( F-87)

1 Introduce piston C, compression spring D and

pressure plate E into oil feed housing 9. Preload and
secure by means of lock plate F.

Note: Install pressure plate E with the spigot facing lock

plate F.

2 Fit plug G with new O-ring and install it.

Torque limit (M14 x 1.5)............25 Nm (19 lbf ft)

Fig 90.

2 Install oil feed housing 9 and fix it provisionally by

means of socket head screws 5, 6 and 7.

Note: Screw in socket head screws only until contact is

obtained. DO NOT TIGHTEN.

3 Fit alignment dowels (M10) into the gearbox housing

via the centre hole of feed housing 9. Introduce stator
shaft 4 until contact is obtained.

Note: Pay attention to the overlapping of the bores.

4 Insert O-ring into the annular groove of oil pump 2/3

and oil it.

5 Insert pump 2/3 over the pump drive shaft and

position it evenly against shoulder by means of
Fig 89.
socket head screws 1 (without O-rings).

Installation - Oil Feed Housing/Transmission 6 Remove socket head screws 1 and equip them with
Pump new greased O-rings.

Fig 92. ( F-89). 7 Fasten transmission pump by means of socket head

screws 1.
1 Install two alignment dowels (M8) (arrowed) and fit
gasket 10. Torque limit............................. 46 Nm (34 lbf ft)

8 Secure oil feed housing 9 by means of socket head

screws 5, 6 and 7 and two hexagonal head screws 8.

Torque limit (5,6, 7)................... 23 Nm (17 lbf ft)

Torque limit (8)......................... 46 Nm (34 lbf ft)

Note: Pay attention to the position of the lifting ring

(arrowed) Fig 91. ( F-88).

F - 87 9803/4160-12 F - 87
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 91.

F - 88 9803/4160-12 F - 88
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 92. Oil Feed Housing and Transmission Pump

F - 89 9803/4160-12 F - 89
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Installation - Torque Converter flange 15, fit disk 14 and, by means of screws 13, pull
the flange evenly against shoulder.
Fig 94. ( F-91).
Torque limit (M8/10.9)............... 34 Nm (25 lbf ft)
1 Install converter bell housing 26 by means of screws
25 after aligning the match marks made during 7 Secure screws 13 by means of lock plate 12.
dismantling.

Torque limit (M10/10.9)............. 68 Nm (50 lbf ft)

2 Assemble drive shaft 18 and diaphragm 22 and

secure with screws 21.

Torque limit (M10/10.9)............. 115 Nm (85 lbf ft)

3 Fasten diaphragm 22 to torque converter 23 by

means of screws 25.

Torque limit (M10/10.9)............. 115 Nm (85 lbf ft)

Note: Apply JCB Threadlocker and Sealer (High strength)

to the threads of screws 94-25.

4 Insert converter assembly until contact is obtained.

Note: Pulse disc of the converter must be positioned

axially to the bore (arrowed) of the inductive transmitter
Fig 93. ( F-90).

Fig 93.

5 Insert ball bearing 20 until contact is obtained and fix

it by means of circlip 19.

6 Fit cover 11 loose over bell housing 26, aligning the

match marks made during dismantling. Install drive

F - 90 9803/4160-12 F - 90
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 94. Torque Converter

Note: For following steps refer to Fig 96. ( F-92).

8 Fasten cover 11 by means of screws 16 and nuts 17.

Torque limit (M10/8.8)........... 46 Nm (34 lbf ft)

9 Mount gasket 14 and fasten cover 13 by means of

screws 12.

Torque limit (M8/8.8)................. 23 Nm (17 lbf ft)

10 Insert converter safety valve into the housing bore as

shown in Fig 95. ( F-91).

Fig 95.

F - 91 9803/4160-12 F - 91
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 96.

F - 92 9803/4160-12 F - 92
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Installation - Duct Plate and Hydraulic Control
Unit

1 Install components 3, 4, 5, 6 and 10.

Note: Pay attention to the orientation and relative positions

of gaskets 4/6 and intermediate plate 5.

Secure duct plate 3 with screws 7, nuts 8 and

washers 9.

2 Fit screw plug (arrowed) with new O-ring and install it

Fig 97. ( F-93).

Torque limit (M16 x 1.5)............ 30 Nm (22 lbf ft)

Fig 97.

3 Fasten hydraulic control unit 2 by means of screws 1.

Torque limit (M6)......... 9.5 Nm (7 lbf ft)

F - 93 9803/4160-12 F - 93
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 98.

F - 94 9803/4160-12 F - 94
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Install Plugs and Oil Level Tube 3 Install cover plate D using a new gasket.

1 Fit plugs A and B with new O-rings and install. Torque limit (M8/8.8).............. 23 Nm (17 lbf ft)

Torque limit (M18 x 1.5) (plug A)..... 50 Nm (37 lbf ft) Equip screw plug E with new O-ring and install.

Torque limit (M26 x 1.5) (plug B)..... 80 Nm (59 lbf ft) Torque limit (M38 x 1.5)......... 140 Nm (103 lbf ft)

Fig 99.
Fig 101.
2 Install oil level tube C using a new gasket.

Torque limit (M8/10.9)............ 34 Nm (25 lbf ft)

Fig 100.

F - 95 9803/4160-12 F - 95
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Install Speed Sensor and Inductive Transmitters

1 Grease O-rings and install speed sensor F.

Torque limit................. 23 Nm (17 lbf ft)

Fig 102.

2 Grease O-rings and install inductive transmitters G, H

and J.

Torque limit................... 30 Nm (22 lbf ft)

Install breather K.

Torque limit................... 12 Nm (9 lbf ft)

Fig 103.

F - 96 9803/4160-12 F - 96
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Hydraulic Control Unit - 13 Remove components 104-31/32 (1 off), 104-33/34 (3

off) and 104-35/ 36 (3 off).
Dismantling

Fig 104. ( F-98).

1 Match-mark relative to each other the relevant

positions of valve housing 1, housing covers 12 and
15, and end covers 2 and 3.

2 Remove socket head screws 5.

Separate duct plate 6, gasket 7, intermediate plate 8

and gasket 9 from the valve housing.

3 Remove retaining clip 10.

4 Remove socket head screws 11 and 14.

Separate cover 2 and gasket 2A from housing 12 and

cable harness 4. Separate cover 3 and gasket 3A
from housing 15.

5 Disconnect cable harness 4 from the pressure

regulators 17 (3 off) and 29 (3 off) and remove.

6 Remove the three socket head screws 18, fixing

plates 19 and pressure regulators 17.

7 Remove the two outermost socket head screws 20

and replace provisionally with adjusting screws.

Remove the remaining socket head screws 20.

8 Separate housing 12 and gasket 13 from valve

housing 1 by loosening the compression tools
uniformly to release the spring loading.

9 Remove components 21/22 (1 off), 23/24 (3 off) and -

25/ 26 (3 off).

10 Remove the three socket head screws 27, fixing

plates 28 and pressure regulators 29.

11 Remove the two outermost socket head screws 30

and replace provisionally with adjusting screws (M5).
Remove the remaining socket head screws 30.

12 Separate housing 15 and gasket 16 from valve

housing 1 by loosening the adjusting screws
uniformly to release the spring loading.

F - 97 9803/4160-12 F - 97
 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 104. Hydraulic Control Unit

F - 98 9803/4160-12 F - 98
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Assembly

Fig 104. ( F-98).

1 Check all components for damage and renew if

necessary.

Prior to installation, check free travel of all moving

parts in the housing.

Oil the components prior to assembly.

Note: Spools can be changed individually.

2 Insert diaphragms 37 (arrowed) with the concave side

showing upward until contact is obtained Fig Fig 106.
105. ( F-99).
4 Assemble gasket 13 and housing cover 12. Position
the housing cover 12 uniformly and secure using
adjusting screws (M5) in the two outermost positions
of screws 20, until contact is obtained. Remove
cylindrical pins fitted at step 3.

Note: Pay attention to the different housing covers. Install

recess 15 mm Ø (arrowed) Fig 107. ( F-99)) facing
the spring 21 of the pressure reducing valve.

Fig 105.

3 Install components 21/22 (1 off), 23/24, (3 off) and 25/

26 (3 off). Preload compression spring of the follow-
on slides 25/26 and locate spool provisionally by
means of cylindrical pins 5,0 mm Ø (arrowed in Fig
106. ( F-99)).

Fig 107.

F - 99 9803/4160-12 F - 99
 Section F - Transmission
Powershift Transmission
WG 160, WG 190
5 Secure housing cover 12 by means of socket head
screws 20 in the remaining positions. Remove the
two adjusting screws and fit the further screws 20.

Torque limit.......................... 5.5 Nm (4 lbf ft).

6 Fit pressure regulators 17 and fix by means of fixing

plates 19 and socket head screws 18.

Note: Install fixing plates with the claw showing downward.

Pay attention to the radial installation position of the
pressure regulators, see Fig 108. ( F-100).

Torque limit........................ 5.5 Nm (4 lbf ft).

Fig 109.

8 Assemble gasket 16 and housing cover 15. Position

the housing cover 15 uniformly against shoulder,
using adjusting screws (M5) in the two outermost
locations for screws 30. Remove the cylindrical pins
fitted at step 7.

Note: Pay attention to the different housing covers. Install

the recess 109-A (19 mm Ø) facing the main pressure
valve 31/ 32.

9 Fasten housing cover 15 by means of socket head

screws 30 in the remaining positions. Remove the
two adjusting screws and fit the further screws 30.
Fig 108.
Torque limit............................... 5.5 Nm (4 lbf ft)
7 Install components 31/32 (1 off), 33/34 (3 off) and 35/
36 (3 off). 10 Fit pressure regulators 29 and fix by means of fixing
plates 28 and socket head screws 27.
Preload compression springs of the follow-on slides
35/36 and locate spool provisionally by means of Note: Install fixing plates with the claw showing downward.
cylindrical pins 5 mm Ø (arrowed in Fig Pay attention to the radial installation position of the
109. ( F-100)). pressure regulators, see Fig 110. ( F-101).

Torque limit............................... 5.5 Nm (4 lbf ft)

F - 100 9803/4160-12 F - 100

 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 110.

11 Connect cable harness 4 to pressure regulators 17 (3

off) and 29 (3 off).
Fig 111.
Note: Pay attention to the installation position of the cable
Note: Pay attention to the difference between gaskets 7
harness.
and 9, see exploded view.
12 Install gasket 2A on housing 12. Fit the harness
2 Insert screens (arrowed) Fig 112. ( F-102)) flush
connector into cover 2 against shoulder, with the
mounted into the bore of intermediate plate 8.
groove facing the guide nose of the cover. Fasten
cover by means of socket head screws 11.
Note: Install screens visible on the side facing duct plate 6.
Torque limit............................... 5.5 Nm (4 lbf ft)

13 Secure harness connector by means of retaining

clamp 10.

14 Fit cover 3 with gasket 3A by means of socket head

screws 14.

Torque limit............................... 5.5 Nm (4 lbf ft)

Intermediate plate with gaskets

1 Fit two alignment dowels (M6) B and install gasket 9.

Note: For procedure to install Coated Intermediate Sheet

Intermediate plate coated sheet ( F-103).

F - 101 9803/4160-12 F - 101

 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 113.

Fig 112.

3 Install intermediate plate 8, screens uppermost,

followed by gasket 7.

4 Install duct plate 6 and fasten it uniformly by means of

socket head screws 5. Remove the alignment dowels
fitted at Step 1.

Torque limit.............................. 9.5 Nm (7 lbf ft)

5 Equip screw plugs (arrowed) with new O-rings and

install them Fig 113. ( F-102).

Torque limit.............................. 6 Nm (4.4 lbf ft)

F - 102 9803/4160-12 F - 102

 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Intermediate plate coated sheet

Fitting the intermediate plate Coated Sheet (without

gaskets). Fig 117. ( F-105).

Note: If the later type Coated Intermediate Sheet is being

installed as a replacement for the earlier Gasket Type, it is
MOST important that it is fitted with the correct Shorter
Torx Screws 5. (See Table 1. Bolt Fitting Chart
( F-104)) The installation procedure for the Gasket Type
intermediate Sheet can be found on the preceding pages.

 

Fig 115.

3 Install intermediate plate 8 screens uppermost. Take

care not to damage the coating.

Fig 114. 4 Install duct plate 6 and fasten it uniformly by means of

socket head screws 5. Remove the alignment dowels
1 Fit two alignment dowels (M6) B. fitted at Step 1

2 Insert screens (arrowed in Fig 115. ( F-103)) Torque limit.............................. 9.5 Nm (7 lbf ft)
flush mounted into the bore of intermediate plate 117-
8. 5 Equip screw plugs (arrowed) with new O-rings and
install them. Fig 116. ( F-104)
Note: Install screens visible on the side facing duct plate 6.
Torque limit.............................. 6 Nm (4.4 lbf ft)

F - 103 9803/4160-12 F - 103

 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 116.

Table 1. Bolt Fitting Chart

Type Length Application Torque
Setting
Torx Screw M6 X 80 Paper gaskets 12 Nm (9 lbf ft)
Torx Screw M6 X 76 Coated sheet 9.5 Nm (7 lbf ft)
Torx Screw M6 X 25 Paper gaskets 12 Nm (9 lbf ft)
Torx Screw M6 X 23 Coated sheet 9.5 Nm (7 lbf ft)

F - 104 9803/4160-12 F - 104

 Section F - Transmission
Powershift Transmission
WG 160, WG 190

Fig 117. Coated Intermediate Plate

F - 105 9803/4160-12 F - 105

 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Clutch Pack Calibration (AEB)

Calibration of the transmission clutch packs must be

carried out at the 1st 100 hour oil change then at every oil
change (1000 hours) or when the ZF controller or the
transmission has been replaced.

The procedure should also be carried out if error codes F5

or F6 are displayed on the EMS.

The calibration is carried out using a procedure called

AEB.

In order to carry out the AEB procedure, the following

conditions MUST be met:

1 The transmission must be hot. (Approximately half

way up the scale).
Fig 118.
Note: It is essential that the temperature is maintained
during the procedure. If the temperature falls below a
preset level, the procedure will abort. In this event, rewarm
the transmission and repeat the procedure.

2 The parking brake must be applied. Press firmly on

the foot brake pedal.

3 The engine should be run at idle.

Note: In some circumstances, idle may be too low, in this

case, the EMS will display “ENGINE RPM”. Increase the
engine speed by 50 RPM and repeat the procedure.

Calibration Procedure

Press the following buttons simultaneously:

UP, DOWN & SETUP/SELECT

then press the following button TWICE:

SETUP/SELECT

The EMS will display the clutch being calibrated and

a timing number.

When the procedure is complete, “AEB PASSED” will

be displayed.

F - 106 9803/4160-12 F - 106

 Section F - Transmission
Powershift Transmission
WG 160, WG 190
Fitting the Inductive Transmitter

Install the inductive transmitter, ensuring that the

clearance between the contact face of the transmitter and
the tip of the teeth on the spur gear is between 0.6 and 0.8
mm. If required, the clearance can be adjusted by the
fitting of a shim using the procedure described below:

Measure the dimension from the tip of the teeth on the spur
gear to the housing face (dimension 1).

Also measure the dimension from the end face to the

shoulder on the inductive transmitter (dimension 2).

Work out the size of the shim required as follows:

Dimension 1 26.20 mm
Required clearance - 0.70 mm

Difference = adjustment dimension 25.50 mm

Dimension 2 26.50 mm
Adjustment dimension - 25.50 mm

Difference = shim size 1.00 mm

Assemble the shim to the inductive transmitter, fit a new O-

ring into the ring groove and screw the inductive
transmitter into the housing.

Fig 119.

F - 107 9803/4160-12 F - 107

 Section F - Transmission

Fault Finding
Functional Testing

The transmission system is controlled by an on-board 5 Connect PR78 B (interrogator unit) to remaining 25-
computer which measures transmission output speed and way female connector.
monitors the driver's actions.
The PR78 A light indicator unit detects the various inputs
Besides making basic decisions on gear shifting, the and outputs to and from the machine's computer and
computer monitors driver commands via accelerator, gear illuminates lights which correspond to the selections the
and direction of travel controls and the kick-down selector. driver has made. In this way the probable fault area of a
These inputs enable the computer to override and defective transmission unit can be immediately identified.
smoothly control any judgements made by the driver which
could have potentially hazardous consequences for the The Drive/Gear Selection Status Lights table shows the
driver or machine. For example, if a driver switches from possible transmission selections that a driver can make
forward 4th gear to reverse drive the computer will switch and also shows the correct status of the lights when each
down the gears to 2nd gear before engaging reverse drive. selection is made. For example, if the driver selected
forward direction gear 2 with the machine stationary the
Because the computer is 'aware' of all the transmission following lamps would illuminate:
functions it is an ideal tool for fault diagnosis on the
transmission system. V, B3, M3 and M4.

The majority of tests on the semi-automatic option can be

carried out with the machine stationary. (With the
automatic transmission option some tests need to be
carried out with the wheels rolling.) The following
equipment is needed for testing the transmission.

1 A computer test harness (892/00865)

2 A test indicator box PR78 A (892/00866)

3 A test interrogator box PR78 B (892/00867)

4 A Fluke 85 digital multimeter

5 A frequency meter.

The transmission computer is located near the fuse box in Fig 1.

the cab. It is accessed as follows:

1 Turn starter switch off and remove the key.

2 Remove the arm rest.

3 Remove 35-way connector 1-C from computer and

connect to test box. Connect 35-way female
connector from test box to computer.

4 Connect PR78 A (light indicator unit) to 25-way

female connector.

F - 108 9803/4160-12 F - 108

 Section F - Transmission
Fault Finding
Functional Testing

Semi - automatic 3 Select neutral drive gear 2 and compare the dots in
the table with the lights illuminated on the indicator
1 With the test equipment connected, insert the starter unit (PR78 A).
key and turn it to the ON position. Do not start the
engine. 4 Work through the gear/drive selection in the table. If a
light should illuminate but doesn't, make a note of the
2 Select neutral drive gear 1 and check that the lights drive and gear selection made and the reference of
illuminate where indicated by the dots in the table. the light which failed to illuminate.

Note: Since this is a static test, light nAb will not illuminate.

  

  

               



















Fig 2. Drive/Gear Selection Status Lights (Semi-automatic Transmissions)

F - 109 9803/4160-12 F - 109

 Section F - Transmission
Fault Finding
Functional Testing

Test Procedure (Automatic) Reverse Gear Lamps Lit

A R + B1 + B2 + B3
To carry out the diagnostic tests on the automatic
transmission the wheels must be turning, i.e. a computer
Note: When kickdown is selected, the WK lamp should
input from the roadspeed transducer (nAb) is required.
light.
Raise the machine so that the road wheels are clear of the
6 If any of the above indications are incorrect, the gear
ground. Support the machine securely on axle stands or
selector control should be connected directly to the
suitable blocks.
test harness as described below and the test
repeated.
Place barriers around the machine and make sure that no
one gets near the machine while it is running.
a Remove the steering wheel.

!MCAUTION b Remove the top fascia of the steering column.

On startup, before selecting drive, allow 5 seconds for c For ease of access, remove the plug from the
the transmission computer to carry out its self- hazard warning light and remove the hazard
diagnosis checks. Failure to do so will result in a delay warning switch.
of up to 10 seconds before drive is engaged.
4-2-2-4 d Remove the plug from the gear control lever and
reconnect to the test harness.
1 Connect the test equipment, see Fig 1. ( F-108).
7 Repeat the checks in step 5.
2 Check that the transmission fluid level is correct, see
Transmission - Section 3 - Routine Maintenance. a If the indications are now correct, the fault lies in
the cab harness (SE). Carry out a continuity check
3 Check that the transmission pressure agrees with the on harness SE, refer to Section C - Electrics.
figure quoted on the transmission date plate (e.g. 16 Repair any open-circuits as necessary then
+ 2 = 18 bar). repeat the checks in step 5.
4 Start the engine. b If the indications are still incorrect, the gear
selector control must be replaced.
5 Check the inputs to the transmission computer by
rotating the gear selector control and observing the c If the indications are correct but B3 fails to light,
middle row of lights on the test indicator box as check the proximity switch on the throttle pedal.
follows: Adjust or replace as necessary.

Forward Gear Lamps Lit d If B3 stays lit when the throttle pedal is depressed
then no up-shifts are permitted.
2 - 1 + kickdown V + B1 + B3 + WK
2-1 V + B1 + B3 8 Check the output from the transmission computer to
3 V + B3 the transmission solenoids by rotating the gear
selector control and observing the top row of lights on
4 V + B2 + B3
the test indicator box as follows:
A V + B1 + B2 + B3
Forward Gear Lamps Lit
Reverse Gear Lamps Lit 2 - 1 + kickdown 
2-1 R + B1 + B3 2-1 M2 + M4 + M5
3 R + B3 3 M3 + M4
4 R + B2 + B3 4 M4 + M5

F - 110 9803/4160-12 F - 110

 Section F - Transmission
Fault Finding
Functional Testing

Forward Gear Lamps Lit d If the indications are incorrect, carry out the
following checks:
A M2 + M4 + M5 (1)
12

(1) With A selected and machine stationary, computer will Faults Check
select 2nd gear Forward.
No reverse gears M1
No forward gears (1, 3) M3
Reverse Gear Lamps Lit
No forward gears (2, 4) M5
2 - 1 + kickdown M1 + M2 + M4
No forward 2, reverse 2 M4
2-1 M1 + M4
No forward 1, reverse 1 M2 (1)
3 M1
4 M1 (1) Only if forward 2, reverse 2 are correct.
A M1 + M4 (1)
13 The frequency output can be measured in each gear
(1) With A selected, if the machine is driven: during the tests in step 9 by connecting a frequency
when F3 is engaged, M3 will light. meter between the nAb and -ve sockets on the test
when F4 is engaged, M5 will light. indicator box.

14 The electrical resistance of the output gear speed

Note: Energising the solenoids causes the transmission to
drive the machine in the gear selected. sensor and turbine speed sensor can be measured
by removing the 35-way connector from the
transmission computer and connecting the digital
9 If any of the indications in step 8 are incorrect,
multimeter between the nAb and -ve sockets on the
operation of the transmission solenoids can be
test indicator box. With the toggle switch on the right-
checked directly as detailed below.
hand side of the test indicator box in the ‘down’
a Remove the connecting links on the test position, the output gear speed sensor is selected,
and when the switch is in the ‘up’ position the turbine
interrogator box. Energise the solenoids by
speed sensor is selected. The resistance of both
connecting to the red (+) terminal as follows:
sensors should be between 1400 and 1600 ohms.
10

Forward Gear Connect To Note: 1. Output gear Frequency or Turbine Frequency;

1 M2 + M3 + M4 depending on which transducer is selected on the test box.
2 M2 + M4 + M5
Note: 2. Illuminates when 1st gear is selected and held. If
3 M3 + M4 it flashes, the selected transducer or associated wiring is
4 M4 + M5 faulty.

11
Note: 3. B3 Illuminates when the throttle pedal is at rest.
Reverse Gear Connect To B3 should go out after 5° of pedal movement; if not, adjust
1 M1 + M2 + M4 proximity switch on pedal linkage. B3 prevents upshifts on
a trailing throttle, i.e. going downhill.
2 M1 + M4
3 M1 Note: 4. Only this lamp will be illuminated when the
transmission has auto-shifted from 2 to 3 by driving the
b Correct selection of the solenoids can be checked machine.
by observing the lights on the test indicator box.
Note: 5. Only this lamp will be illuminated when the
c If the indications are correct and the machine transmission has auto-shifted from 2 to 4 by driving the
drives in all gears then the transmission computer machine.
is faulty.

F - 111 9803/4160-12 F - 111

 Section F - Transmission
Fault Finding
Functional Testing

Fig 3. Drive/Gear Selection Status Lights (Automatic Transmissions)

F - 112 9803/4160-12 F - 112

 Section F - Transmission
Fault Finding
Transmission Fault Finding

Transmission Fault Finding

Fault:
Table 1. All the lights on PR78 A failed ( F-113)
Table 2. Some or all of the 'B' lights failed when gear selector switch rotated ( F-114)
Table 3. `V' light failed when forward selected ( F-114)
Table 4. `As' light failed when neutral selected ( F-115)
Table 5. `R' light failed when reverse selected ( F-115)
Table 6. Some or all of the `M' lights failed during gear and drive selection ( F-115)
Table 7. `SKD' light failed on selection ( F-118)
Table 8. `SDA' Light failed on selection ( F-118)

After performing all the tests in the Drive/Gear Selection

Status Lights table, some or all of the lights failed.

Table 1. All the lights on PR78 A failed

Check Action
1 Turn starter switch off. Observe lights M1 to M5 YES: Check 2.
on top row of PR78 A. Turn starter switch on.
Did M1 to M5 flash?
NO: Check 3.
2 Press the Transmission Dump and Kickdown YES: Check 6.
buttons on the loader control lever. Did SDA
and SKD illuminate?
NO: Check 4.
3 Are fuses 100 and 101 in locations A4 and C3 YES: Check 4.
intact?
NO: Replace fuse(s) and repeat check 1.
4 Do all the lights on PR78 A still fail? YES: Check 5.
NO: Check FF table relevant to lights which do fail.
5 Is there battery voltage between sockets 1 and YES: Replace PR78 A.
13 on PR78 A?
NO: Check 6.
6 Remove 8-way connector from control lever and YES: Check 7.
fit 8-way connector from test harness. Repeat
tests. Do all lights still fail?
NO: Replace control lever.
7 Is there continuity along wire 9504? YES: Replace computer.
NO: Replace wire 9504 or appropriate harness.

F - 113 9803/4160-12 F - 113

 Section F - Transmission
Fault Finding
Transmission Fault Finding
Table 2. Some or all of the 'B' lights failed when gear selector switch rotated
Check Action
1 Is the battery voltage present at the appropriate YES: Check 3.
socket on PR78 B?
NO: Check 2.
2 Is the battery voltage present between sockets YES: Replace PR78 A.
1 and 13 on PR78 A?
NO: Replace test harness.
3 Remove 8-way connector from control lever and YES: Check 4.
fit 8-way connector from test harness. Repeat
test.Do any 'B' lights fail?
NO: Replace the machine connector SE.
4 Rotate the gear selector switch. Does B1 YES: Check 6.
illuminate?
NO: Check 5.
5 Is there continuity on wire 9524? YES: Replace the Control Lever.
NO: Replace or repair the appropriate harness.
6 Rotate the gear selector switch. Does B2 YES: Check 8.
illuminate?
NO: Check 7.
7 Is there continuity on wire 9528? YES: Replace the Control Lever.
NO: Replace or repair the appropriate harness.
8 Rotate the gear selector switch. Does B3 YES: Check FF table relevant to lights which do fail.
illuminate?
NO: Check 9.
9 Is there continuity on wire 9508? YES: Check 10.
NO: Replace or repair the appropriate harness.
10 Is there continuity on wire 9508A? YES: Check the wire link between wires 9508 and
9508A.
NO: Replace or repair the appropriate harness.

Table 3. `V' light failed when forward selected

Check Action
1 Is there continuity on wire 9512? YES: Check 2.
NO: Replace or repair the appropriate harness.
2 Remove 8-way connector from control lever and YES: Replace the Control Lever.
fit 8-way connector from test harness. Repeat
test. Does V light still fail when forward
selected?
NO: Replace or repair the appropriate harness.

F - 114 9803/4160-12 F - 114

 Section F - Transmission
Fault Finding
Transmission Fault Finding
Table 4. `As' light failed when neutral selected
Check Action
1 Is there continuity on wire 9674? YES: Check 2.
NO: Replace or repair the appropriate harness.
2 Remove 8-way connector from control lever and YES: Replace Control Lever.
fit 8-way connector from test harness. Repeat
test. Does As light still fail when neutral
selected?
NO: Replace the machine connector SE.

Note: If machine still refuses to start, suspect wire 9584

and neutral start relay.

Table 5. `R' light failed when reverse selected

Check Action
1 Is there continuity on wire 9658? YES: Check 2.
NO: Replace or repair the appropriate harness.
2 Remove 8-way connector from control lever and YES: Replace Control Lever.
fit 8-way connector from test harness. Repeat
test. Does R light still fail when reverse
selected?
NO: Replace the machine connector SE.

Table 6. Some or all of the `M' lights failed during gear and drive selection
Check Action
1 Did all 'M' lights fail regardless of gear and drive YES: Check 3.
selection?
NO: Check 2.
2 Follow appropriate procedure below, for light
which has failed. ensure that appropriate gear is
selected to drive light.
3 Is there battery voltage at appropriate socket on YES: Check 5.
PR78 B?
NO: Check 4.
4 Is there battery voltage between sockets 1 and YES: Replace PR78 A.
13 on PR78 A?
NO: Check 5.
5 Remove 8-way connector from control lever and YES: Check 6.
fit 8-way connector from test harness. Repeat
tests. Do all lights still fail?
NO: Replace Control Lever.
6 Is there continuity along wire 9504? YES: Replace computer.
NO: Replace wire 9504 or appropriate harness.
7 Select Reverse drive. Does M1 fail? YES: Check 8.

F - 115 9803/4160-12 F - 115

 Section F - Transmission
Fault Finding
Transmission Fault Finding

Check Action
NO: Check fault-finding procedure appropriate to failed
light.
8 Select Forward drive. Measure voltage between YES: Check 9.
coil end of wire 9434 and a good earth.Is it
within range 150-180mV?
NO: Check 10.
9 Select Reverse drive. Measure voltage between YES: Replace the coil.
coil end of wire 9434 and a good earth. Is it
equal to the battery voltage?
NO: Replace the computer.
10 Is there continuity on wire 9434? YES: Check 11.
NO: Replace or repair the appropriate harness.
11 Remove 8-way connector from control lever and YES: Replace the harness connector.
fit 8-way connector from test harness. Repeat
tests.Does M1 still fail?
NO: Replace the control lever.
12 Select Reverse drive. Does M2 fail? YES: Check 13.
NO: Check fault-finding procedure appropriate to failed
light.
13 Select Forward drive. Measure voltage between YES: Check 14.
coil end of wire 9438 and a good earth. Is it
within range 150-180mV?
NO: Check 15.
14 Select Reverse drive. Measure voltage between YES: Replace the coil.
coil end of wire 9438 and a good earth.Is it
equal to the battery voltage?
NO: Replace the computer.
15 Is there continuity on wire 9434? YES: Check 16.
NO: Replace or repair the appropriate harness.
16 Remove 8-way connector from control lever and YES: Replace the harness connector.
fit 8-way connector from test harness. Repeat
tests.Does M2 still fail?
NO: Replace the control lever.
17 Select Reverse drive. Does M3 fail? YES: Check 18.
NO: Check fault-finding procedure appropriate to failed
light.
18 Select Forward drive. Measure voltage between YES: Check 19.
coil end of wire 9442 and a good earth.Is it
within range 150-180mV?
NO: Check 20.
19 Select Reverse drive. Measure voltage between YES: Replace the coil.
coil end of wire 9442 and a good earth.Is it
equal to the battery voltage?

F - 116 9803/4160-12 F - 116

 Section F - Transmission
Fault Finding
Transmission Fault Finding

Check Action
NO: Replace the computer.
20 Is there continuity on wire 9442? YES: Check 21.
NO: Replace or repair the appropriate harness.
21 Remove 8-way connector from control lever and YES: Replace the harness connector.
fit 8-way connector from test harness. Repeat
tests.Does M3 still fail?
NO: Replace the control lever.
22 Select Reverse drive. Does M4 fail? YES: Check 23.
NO: Check fault-finding procedure appropriate to failed
light.
23 Select Forward drive. Measure voltage between YES: Check 24.
coil end of wire 9446 and a good earth.Is it
within range 150-180mV?
NO: Check 25.
24 Select Reverse drive. Measure voltage between YES: Replace the coil.
coil end of wire 9446 and a good earth.Is it
equal to the battery voltage?
NO: Replace the computer.
25 Is there continuity on wire 9446? YES: Check 26.
NO: Replace or repair the appropriate harness.
26 Remove 8-way connector from control lever and YES: Replace the harness connector.
fit 8-way connector from test harness. Repeat
tests.Does M4 still fail?
NO: Replace the control lever.
27 Select Reverse drive. Does M5 fail? YES: Check 28.
NO: Check fault-finding procedure appropriate to failed
light.
28 Select Forward drive. Measure voltage between YES: Check 29.
coil end of wire 9430 and a good earth.Is it
within range 150-180mV?
NO: Check 30.
29 Select Reverse drive. Measure voltage between YES: Replace the coil.
coil end of wire 9430 and a good earth.Is it
equal to the battery voltage?
NO: Replace the computer.
30 Is there continuity on wire 9430? YES: Check 31.
NO: Replace or repair the appropriate harness.
31 Remove 8-way connector from control lever and YES: Replace the harness connector.
fit 8-way connector from test harness. Repeat
tests.Does M5 still fail?
NO: Replace the control lever.

F - 117 9803/4160-12 F - 117

 Section F - Transmission
Fault Finding
Transmission Fault Finding
Table 7. `SKD' light failed on selection
Check Action
1 Select SKD on the control lever. Does SKD on YES: Check 5.
PR78 A illuminate?
NO: Check 2.
2 Measure the voltage on pin 1 of harness YES: Replace the computer.
connector SE. Is it equal to the battery voltage?
NO: Check 3.
3 Remove 8-way connector from control lever and YES: Check 4.
fit 8-way connector from test harness. Is battery
voltage now on SE pin 1?
NO: Replace the control lever.
4 Is there continuity on wire 9536? YES: Replace the harness connector.
NO: Replace or repair the appropriate harness.
5 Select SKD on loader control lever. Does SKD YES: No faults in SKD circuit.
on PR78 A illuminate?
NO: Check 6.
6 Measure the voltage on pin 1 of harness YES: Check 9536/9536A splice.
connector SE. Is it equal to the battery voltage?
NO: Check 7.
7 Is there continuity along wire 9612A between YES: Check 8.
fuse 3C and loader control lever switch?
NO: Replace or repair the appropriate harness.
8 Is there continuity along wire 9536A between YES: Replace switch.
computer and loader control lever switch?
NO: Replace or repair the appropriate harness.

Table 8. `SDA' Light failed on selection

Check Action
1 Is Dump Inhibit switch in cab roof selected? YES: Deselect and check 2.
NO: Check 2.
2 Press Dump switch on Loader Control. Does YES: Check 8.
SDA illuminate?
NO: Check 3.
3 Has 10 Amp. fuse at location 4A blown? YES: Replace fuse with one of correct value.
NO: Check 4.
4 Check continuity of wire between fuse holder YES: Check 5.
and splice SS. Is it O.K.?
NO: Repair or replace the harness.
5 Check continuity of wire 101M between splice YES: Check 6.
SS and Dump Button terminal 1. Is it O.K.?
NO: Repair or replace the harness.

F - 118 9803/4160-12 F - 118

 Section F - Transmission
Fault Finding
Transmission Fault Finding

Check Action
6 Select voltage range on the meter. Connect YES: Check 7.
between terminal 2 of Dump Button TJ and a
good earth. Does battery voltage register when
Dump Button is pressed?
NO: Replace dump switch.
7 Does the battery voltage appear at the computer YES: Replace the computer.
end of wire 9600 when the Dump Button is
pressed?
NO: Repair wire 9600 or replace the harness.
8 Select Neutral and start the engine. Apply YES: SDA function O. K.
footbrake. Does the SDA lamp illuminate?
NO: Check 9.
9 Check continuity of wire 101A between splice YES: Check 10.
SS and Dump Pressure Switch (Dump Inhibit)
in the cab roof. Is continuity O.K.?
NO: Repair or replace the harness.
10 Check continuity between wire 101A and wire YES: Check 11.
840. Does reading change from an infinite
reading to almost zero Ohms when the Dump
Inhibit switch is depressed?
NO: Replace the Dump Inhibit switch.
11 Check continuity of wire 840. Is it O.K.? YES: Check 12.
NO: Repair or replace the harness.
12 Connect meter across pins 1 and 2 of the dump YES: Check 13.
switch at connector FD1. Does resistance
reading change dramatically when switch is
operated?
NO: Replace the switch.
13 Check continuity of wire 9600. Is it O.K.? YES: Replace computer.
NO: Repair or replace the harness.

F - 119 9803/4160-12 F - 119

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Codes (4WG-160/190/210)

The Electronic Monitoring System (EMS) will display an Note: TCU = Transmission Control Unit
error code in the event of a fault developing in the
transmission system. Further details of the EMS system can be found in Section
C - Electrics.
The code will be displayed on the top line of the EMS
display panel in the format: ZFCB ERROR?

Fault Fault Possible Cause Action

Code
11 Logical error at gear range signal. Cable from shift lever to TCU is Check cables from TCU to shift lever.
broken.
TCU detected a wrong signal Cable is defective and is contacted Check signal combinations of shift
combination for the gear range. to battery voltage or vehicle earth. positions for gear range.
Shift lever is defective.
12 Logical error at direction select Cable from shift lever to TCU is Check cables from TCU to shift lever.
signal. broken.
TCU detected a wrong signal Cable is defective and is contacted Check signal combinations of shift lever
combination for the direction. to battery voltage or earth. F-N-R.
Shift lever is defective.
13 Logical error at engine derating Check engine derating device.
device.
TCU detected no reaction of
engine while derating device
active.
15 Logical error at direction select Cable from shift lever 2 to TCU is Check cables from TCU to shift lever.
signal 2. Shift lever. broken.
TCU detected a wrong signal Cable is defective and is contacted Check signal combinations of shift lever
combination to the direction. to battery voltage or vehicle earth. positions F-N-R.
Shift lever is defective.
16 Logical error at axle connection. Axle can’t be connected or Check cables from TCU to feedback
disconnected due to mechanical axle connection switch.
problem.
Feedback axle connection One of the cables from feedback Check signals of the feedback axle
measured by TCU and output axle connection switch to TCU is connection switch.
signal axle connection don’t fit. broken.
17 Short circuit to vehicle earth at Cable is defective and is contacted Check cables from TCU to customer
customer specific function No. 1. to vehicle earth. specific function No. 1 device.
TCU detected a wrong voltage at Customer specific function No. 1 Check connectors from customer
the output pin, that looks like a device has an internal defect. specific function No. 1 to TCU.
short circuit to vehicle earth.
18 Short circuit to battery voltage at Cable is defective and is contacted Check cables from TCU to customer
customer specific function No. 1. to battery voltage. specific function No. 1 device.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
18 TCU detected a wrong voltage at Customer specific function No. 1 Check connectors from customer
Cont’d. the output pin, that looks like a device has an internal defect. specific function No. 1 to TCU.
short circuit to battery voltage.
Connector pin is contacted to Check resistance of customer specific
battery voltage. function No. 1 device.
19 Open circuit to battery voltage at Cable is defective and has no Check cables from TCU to customer
customer specific function No. 1. connection to TCU. specific function No. 1 device.
TCU detected a wrong voltage at Customer specific function No. 1 Check connectors from customer
the output pin, that looks like a device has an internal defect. specific function No. 1 to TCU.
open circuit for this output pin.
Connector has no connection to Check resistance of customer specific
TCU. function No. 1 device.
1A Short circuit to vehicle earth at Cable is defective and is contacted Check cables from TCU to customer
customer specific function No. 2. to vehicle earth. specific function No. 2 device.
TCU detected a wrong voltage at Customer specific function No. 2 Check connectors from customer
the output pin, that looks like a device has an internal defect. specific function No. 2 to TCU.
short circuit to vehicle earth.
Connector pin is contacted to Check resistance of customer specific
vehicle earth. function No. 2 device.
1B Short circuit to battery voltage at Cable is defective and is contacted Check cables from TCU to customer
customer specific function No. 2. to battery voltage. specific function No. 2 device.
TCU detected a wrong voltage at Customer specific function No. 2 Check connectors from customer
the output pin, that looks like a device has an internal defect. specific function No. 2 to TCU.
short circuit to battery voltage.
Connector pin is contacted to Check resistance of customer specific
battery voltage. function No. 2 device.
1C Open circuit to battery voltage at Cable is defective and has no Check cables from TCU to customer
customer specific function No. 2. connection to TCU. specific function No. 2 device.
TCU detected a wrong voltage at Customer specific function No. 2 Check connectors from customer
the output pin, that looks like a device has an internal defect. specific function No. 2 to TCU.
open circuit for this output pin.
Connector has no connection to Check resistance of customer
TCU. specificfunction No. 2 device.
1D Short circuit to vehicle earth at Cable is defective and is contacted Check cables from TCU to customer
to vehicle earth. specific function No. 3 device.
customer specific function No. 3.
TCU detected a wrong voltage at Customer specific function No. 3 Check connectors from customer
the output pin, that looks like a device has an internal defect. specific function No. 3 to TCU.
short circuit to vehicle earth.
Connector pin is contacted to Check resistance of customer specific
vehicle earth. function No. 3 device.
1E Short circuit to battery voltage at Cable is defective and is contacted Check cables from TCU to customer
customer specific function No. 3. to battery voltage. specific function No. 3 device.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
1E TCU detected a wrong voltage at Customer specific function No. 3 Check connectors from customer
Cont’d. the output pin, that looks like a device has an internal defect. specific function No. 3 to TCU.
short circuit to battery voltage.
Connector pin is contacted to Check resistance of customer specific
battery voltage. function No. 3 device.
1F Open circuit to battery voltage at Cable is defective and has no Check cable from TCU to sensor.
customer specific function No. 3. connection to TCU.
TCU detected a wrong voltage at Customer specific function No. 3 Check connectors.
the output pin, that looks like a device has an internal defect.
open circuit for this output pin.
Connector pin is contacted to Check load sensor.
battery voltage.
23 Short circuit to battery voltage at Cable is defective and is contacted Check cables from TCU to customer
load sensor input. to battery voltage. specific function No. 3 device.
The measured voltage too high. Load sensor has an internal Check connectors from customer
defect. specific function No. 3 to TCU.
Connector has no connection to Check resistance of customer specific
TCU. function No. 3 device.
24 Short circuit to vehicle earth or Cable has no connection to TCU. Check cable from TCU to sensor.
open circuit at load sensor input.
The measured voltage too low. Load sensor has an internal Check connectors.
defect.
Connector pin is contacted to Check load sensor.
vehicle earth or is broken.
25 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit to transmission sump to battery voltage. sensor.
temperature sensor input.
The measured voltage is too high. Cable has no connection to TCU. Check the connectors.
Temperature sensor has an Check the temperature sensor.
internal defect.
Connector pin is contacted to
battery voltage or is broken.
26 Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
transmission sump temperature to vehicle earth. sensor.
sensor input.
The measure voltage is too low. Temperature sensor has an Check the connectors.
internal defect.
Connector pin is contacted to Check the temperature sensor.
vehicle earth.
27 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit at converter output to battery voltage. sensor.
temperature sensor input.
The measured voltage is too high. Cable has no connection to TCU. Check the connectors.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
27 Temperature sensor has an Check the temperature sensor.
Cont’d. internal defect.
Connector pin is contacted to
battery voltage or is broken.
28 Short circuit to earth at converter Cable is defective and is contacted Check the cable from TCU to the
output temperature sensor input. to vehicle earth. sensor.
The measured voltage is too low. Temperature sensor has an Check the connectors.
internal defect.
Connector pin is contacted to Check the temperature sensor.
vehicle earth.
29 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit at parking brake to battery voltage. sensor.
sensor input.
The measured voltage is too high. Cable has no connection to TCU. Check the connectors.
Temperature sensor has an Check the temperature sensor.
internal defect.
Connector pin is contacted to
battery voltage or is broken.
2A Short circuit to vehicle earth Cable is defective and is contacted Check the cable from TCU to the
parking brake sensor input. to vehicle earth. sensor.
The measured voltage is too low. Temperature sensor has an Check the connectors.
internal defect.
Connector pin is contacted to Check the parking brake sensor.
vehicle earth.
2B Inch sensor-signal mismatch. Cable is defective. Check the cable from TCU to the
sensor.
The measured voltage from CCO Sensor has an internal defect. Check the connectors.
and CCO2 signal doesn’t match.
Check the sensor.
31 Short circuit battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit at engine speed input. to battery voltage. sensor.
TCU measures a voltage higher Cable has no connection to TCU. Check the connectors.
than 7.00V at speed input pin.
Speed sensor has an internal Check the speed sensor.
defect.
Connector pin is contacted to
battery voltage or is broken.
32 Short circuit to earth at engine Cable is defective and is contacted Check the cable from TCU to the
speed input. to vehicle earth. sensor.
TCU measures a voltage less than Speed sensor has an internal Check the connectors.
0.45V at speed input pin. defect.
Check the speed sensor.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
33 Logical error at engine speed Cable/connector is defective and Check the cable from TCU to the
input. has a bad contact sensor.
TCU measures a voltage less than Speed sensor has an internal Check the connectors.
0.45V at speed input pin. defect.
Sensor gap is the wrong size. Check the speed sensor.
Check the sensor gap.
34 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit at turbine speed input. to battery voltage. sensor.
TCU measures a voltage higher Cable has no connection to TCU. Check the connectors.
than 7.00V at speed input pin.
Speed sensor has an internal Check the speed sensor.
defect.
Connector pin is contacted to
battery voltage or has no contact.
35 Short circuit to earth at turbine Cable/connector is defective and is Check the cable from TCU to the
speed input. contacted to vehicle earth. sensor.
TCU measures a voltage less than Speed sensor has an internal Check the connectors.
0.45V at speed input pin. defect.
Check the speed sensor.
36 Logical error at turbine speed Cable/connector is defective and Check the cable from TCU to the
input. has a bad contact sensor.
TCU measures an engine speed Speed sensor has an internal Check the connectors.
over a threshold and the next defect.
moment the measured speed is
zero.
Sensor gap is the wrong size. Check the speed sensor.
Check the sensor gap.
37 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit at internal speed input. to battery voltage. sensor.
TCU measures a voltage higher Cable has no connection to TCU. Check the connectors.
than 7.00V at speed input pin.
Speed sensor has an internal Check the speed sensor.
defect.
Connector pin is contacted to
battery voltage or has no contact.
38 Short circuit to earth at internal Cable/connector is defective and is Check the cable from TCU to the
speed input. contacted to vehicle earth. sensor.
TCU measures a voltage less than Speed sensor has an internal Check the connectors.
0.45V at speed input pin. defect.
Check the speed sensor.
39 Logical error at internal speed Cable/connector is defective and Check the cable from TCU to the
input. has a bad contact sensor.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
39 TCU measures an engine speed Speed sensor has an internal Check the connectors.
Cont’d. over a threshold and the next defect.
moment the measured speed is
zero.
Sensor gap is the wrong size. Check the speed sensor.
Check the sensor gap.
3A Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the
open circuit at output speed input. to battery voltage. sensor.
TCU measures a voltage higher Cable has no connection to TCU. Check the connectors.
than 12.5V at speed input pin.
Speed sensor has an internal Check the speed sensor.
defect.
Connector pin is contacted to
battery voltage or has no contact.
3B Short circuit to earth at output Cable/connector is defective and is Check the cable from TCU to the
speed input. contacted to vehicle earth. sensor.
TCU measures a voltage less than Speed sensor has an internal Check the connectors.
1.00V at speed input pin. defect.
Check the speed sensor.
3C Logical error at output speed input. Cable/connector is defective and Check the cable from TCU to the
has a bad contact sensor.
TCU measures an engine speed Speed sensor has an internal Check the connectors.
over a threshold and the next defect.
moment the measured speed is
zero.
Sensor gap is the wrong size. Check the speed sensor.
Check the sensor gap.
3D Turbine speed zero doesn’t fit to
other speed signals
3E Output speed zero does not fit to Speed sensor has an internal Check the sensor signal of the output
other speed signals. defect. speed sensor.
If transmission is not neutral and Sensor gap is the wrong size. Check the sensor gap of the output
the shifting has finished, TCU speed sensor.
measures output speed zero and
turbine speed or internal speed not
equal to zero.
Check the sensor gap of the output
speed sensor.
54 DCTI timeout. Interference on CAN-Bus. Check cluster controller.
Timeout of CAN-message MDU1 CAN wire/connector is broken. Check wire of CAN-Bus.
from cluster controller.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
54 CAN wire/connector is defective Check cable to cluster controller.
Cont’d. and has contact with vehicle earth
or battery voltage.
71 Short circuit to battery voltage at Cable/connector is defective and is Check the cable from TCU to the
clutch K1. contacted to battery voltage. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of K1 valve is too high.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
72 Short circuit to earth at clutch K1. Cable/connector is defective and is Check the cable from TCU to the
contacted to vehicle earth. gearbox.
The measured resistance value of Cable/connector is defective and is Check the connectors from TCU to the
the valve is out of limit, the voltage contacted to another regulator gearbox.
of K1 valve is too low. output of the TCU.
Regulator has an internal defect. Check the regulator resistance.
Check the internal wire harness of the
gearbox.
73 Open circuit at clutch K1. Cable/connector is defective and Check the cable from TCU to the
has no contact to TCU. gearbox.
The measured value of the valve Regulator has an internal defect. Check the connectors from TCU to the
isout of limit. gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
74 Short circuit to battery voltage at Cable/connector is defective and Check the cable from TCU to the
clutch K2. has contact to battery voltage. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of K2 valve is too high.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
75 Short circuit to earth at clutch K2. Cable/connector is defective and Check the cable from TCU to the
has contact to vehicle earth. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of K2 valve is too low.
Cable/connector is defective and Check the regulator resistance.
has contact to another regulator
output of the TCU.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
75 Check the internal wire harness of the
Cont’d. gearbox.
76 Open circuit at clutch K2. Cable/connector is defective and Check the cable from TCU to the
has no contact to TCU. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit. gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
77 Short circuit to battery voltage at Cable/connector is defective and Check the cable from TCU to the
clutch K3. has contact to battery voltage. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of K3 valve is too high.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
78 Short circuit to earth at clutch K3. Cable/connector is defective and is Check the cable from TCU to the
contacted to vehicle earth. gearbox.
The measured resistance value of Cable/connector is defective and Check the connectors from gearbox to
the valve is out of limit, the voltage has contact to another regulator the TCU
of K3 valve is too low. output of the TCU.
Regulator has an internal defect. Check the regulator resistance.
Check the internal wire harness of the
gearbox.
79 Open circuit at clutch K3. Cable/connector is defective and Check the cable from TCU to the
has no contact to TCU. gearbox.
The measured resistance value is Regulator has an internal defect. Check the connectors from TCU to the
out of limit. gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
7A Short circuit to battery voltage at
converter clutch.
7B Short circuit to vehicle earth at
converter clutch.
7C Open circuit at converter clutch.
81 Short circuit to battery voltage at Cable/connector is defective and Check the cable from TCU to the
clutch K4. has contact to battery voltage. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of K3 valve is too high.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
81 Check the regulator resistance.
Cont’d.
Check the internal wire harness of the
gearbox.
82 Short circuit to earth at clutch K4. Cable/connector is defective and is Check the cable from TCU to the
contacted to vehicle earth. gearbox.
The measured resistance value of Cable/connector is defective and Check the connectors from TCU to the
the valve is out of limit, the voltage has contact to another regulator gearbox.
of K4 valve is too low. output of the TCU.
Regulator has an internal defect. Check the regulator resistance.
Check the internal wire harness of the
gearbox.
83 Open circuit at clutch K4. Cable/connector is defective and Check the cable from TCU to the
has no contact to TCU. gearbox.
The measured resistance of the Regulator has an internal defect. Check the connectors from TCU to the
valve is out of limit. gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
84 Short circuit to battery voltage at Cable/connector is defective and Check the cable from TCU to the
clutch KV. has contact to battery voltage. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of KV valve is too high.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
85 Short circuit to earth at clutch KV. Cable/connector is defective and is Check the cable from TCU to the
contacted to vehicle earth. gearbox.
The measured resistance value of Cable/connector is defective and Check the connectors from TCU to the
the valve is out of limit, the voltage has contact to another regulator gearbox.
of KV valve is too low. output of the TCU.
Regulator has an internal defect. Check the regulator resistance.
Check the internal wire harness of the
gearbox.
86 Open circuit at clutch KV. Cable/connector is defective and Check the cable from TCU to the
has no contact to TCU. gearbox.
The measured resistance of the Regulator has an internal defect. Check the connectors from TCU to the
valve is out of limit. gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
87 Short circuit to battery voltage at Cable/connector is defective and Check the cable from TCU to the
clutch KR. has contact to battery voltage. gearbox.
The measured resistance value of Regulator has an internal defect. Check the connectors from TCU to the
the valve is out of limit, the voltage gearbox.
of KR valve is too high.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
88 Short circuit to earth at clutch KR. Cable/connector is defective and is Check the cable from TCU to the
contacted to vehicle earth. gearbox.
The measured resistance value of Cable/connector is defective and Check the connectors from TCU to the
the valve is out of limit, the voltage has contact to another regulator gearbox.
of KR valve is too low. output of the TCU.
Regulator has an internal defect. Check the regulator resistance.
Check the internal wire harness of the
gearbox.
89 Open circuit at clutch KR. Cable/connector is defective and Check the cable from TCU to the
has no contact to TCU. gearbox.
The measured resistance of the Regulator has an internal defect. Check the connectors from TCU to the
valve is out of limit. gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
91 Short circuit to earth at the reverse Cable is defective and is contacted Check the cable from TCU to the
warning alarm relay. to vehicle earth. reverse alarm device.
TCU detected a wrong voltage at Reverse alarm device has an Check the connectors from reverse
the output pin, that looks like a internal defect. alarm device to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the reverse
vehicle earth. alarm device.
92 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
the alarm warning relay. to battery voltage. reverse alarm device.
Reverse alarm device has an Check the connectors from reverse
internal defect. alarm device to the TCU.
Connector pin is connected to Check the resistance of the reverse
battery voltage. alarm device.
93 Open circuit at the reverse warning Cable is defective and has no Check the cable from TCU to the
alarm relay. connection to the TCU. reverse alarm device.
TCU detected a wrong voltage at Reverse alarm device has an Check the connectors from reverse
the output pin, that looks like a internal defect. alarm device to the TCU.
short circuit to battery voltage.
Connector has no connection to Check the resistance of the reverse
the TCU. alarm device.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
94 Short circuit at starter interlock Cable is defective and is contacted Check the cable from TCU to the starter
relay. to vehicle earth. interlock relay.
TCU detected a wrong voltage at Starter interlock relay has an Check the connectors from starter
the output pin, that looks like a internal defect. interlock relay to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the starter
vehicle earth. interlock relay.
95 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the starter

starter interlock relay. to battery voltage. interlock relay.

TCU detected a wrong voltage at Starter interlock relay has an Check the connectors from starter
the output pin, that looks like a internal defect. interlock relay to the TCU.
short circuit to battery voltage.
Connector pin is connected to Check the resistance of the starter
battery voltage. interlock relay.
96 Open circuit at starter interlock Cable is defective and has no Check the cable from TCU to the starter
relay. connection to the TCU. interlock relay.
TCU detected a wrong voltage at Starter interlock relay has an Check the connectors from starter
the output pin, that looks like an internal defect. interlock relay to the TCU.
open circuit for this output pin.
Connector has no connection to Check the resistance of the starter
TCU. interlock relay.
9A Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
converter lock up clutch solenoid. to vehicle earth. converter clutch solenoid.
TCU detected a wrong voltage at Converter clutch solenoid has an Check the connectors from converter
the output pin, that looks like a internal defect. clutch solenoid to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the converter
vehicle earth. clutch solenoid.
9B Open circuit at converter lock up Cable is defective and has no Check the cable from TCU to the
clutch solenoid. connection to the TCU. converter clutch solenoid.
TCU detected a wrong voltage at Converter clutch solenoid has an Check the connectors from converter
the output pin, that looks like an internal defect. clutch solenoid to the TCU.
open circuit for this output pin.
Connector has no connection to Check the resistance of the converter
TCU. clutch solenoid.
9C Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
converter lockup clutch. to battery voltage. converter clutch solenoid.
TCU detected a wrong voltage at Converter clutch solenoid has an Check the connectors from converter
the output pin, that looks like a internal defect. clutch solenoid to the TCU.
short circuit to battery voltage.
Connector pin is connected to Check the resistance of the converter
battery voltage. clutch solenoid.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
9D Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
retarder solenoid. to vehicle earth. retarder solenoid.
TCU detected a wrong voltage at Retarder solenoid has an internal Check the connectors from retarder
the output pin, that looks like a defect. solenoid to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the retarder
vehicle earth. solenoid.
9E Open circuit at retarder solenoid. Cable is defective and has no Check the cable from TCU to the
connection to the TCU. retarder solenoid.
TCU detected a wrong voltage at Retarder solenoid has an internal Check the connectors from retarder
the output pin, that looks like an defect. solenoid to the TCU.
open circuit for this output pin.
Connector has no connection to Check the resistance of the retarder
TCU. solenoid.
9F Short circuit to battery voltage at able is defective and is contacted Check the cable from TCU to the
retarder clutch. to battery voltage. converter clutch solenoid.
TCU detected a wrong voltage at Retarder solenoid has an internal Check the connectors from retarder
the output pin, that looks like a defect solenoid to the TCU.
short circuit to battery voltage.
Connector pin is connected to Check the resistance of the retarder
battery voltage. solenoid.
A1 Short circuit to vehicle earth at diff Cable is defective and is contacted Check the cable from TCU to the diff
lock or axle connection solenoid. to vehicle earth. lock solenoid.
TCU detected a wrong voltage at Difflock solenoid has an internal Check the connectors from diff lock
the output pin, that looks like a defect. solenoid to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the diff lock
vehicle earth. solenoid.
A2 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the diff
diff lock or axle connection to battery voltage. lock solenoid.
solenoid.
TCU detected a wrong voltage at Difflock solenoid has an internal Check the connectors from diff lock
the output pin, that looks like a defect. solenoid to the TCU.
short circuit to battery voltage.
Connector pin is connected to Check the resistance of the diff lock
battery voltage. solenoid.
A3 Open circuit at diff lock or axle Cable is defective and has no Check the cable from TCU to the diff
connection solenoid. connection to the TCU. lock solenoid.
TCU detected a wrong voltage at Difflock solenoid has an internal Check the connectors from diff lock
the output pin, that looks like an defect. solenoid to the TCU.
open circuit for this output pin.
Connector has no connection to Check the resistance of the diff lock
TCU. solenoid.

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 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
A4 Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
warning signal output. to vehicle earth. warning device.
TCU detected a wrong voltage at Warning device has an internal Check the connectors from warning
the output pin, that looks like a defect. device to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the warning
vehicle earth. device.
A5 Open circuit at warning signal Cable is defective and has no Cable is defective and has no
output. connection to the TCU. connection to the TCU.
the output pin, that looks like an Warning device has an internal Check the connectors from warning
open circuit for this output pin. defect. device to the TCU.
Connector has no connection to Check the resistance of the warning
TCU. device.
A6 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
warning signal output. to battery voltage. warning device.
TCU detected a wrong voltage at Warning device has an internal Check the connectors from warning
the output pin, that looks like a defect. device to the TCU.
short circuit to battery voltage.
Connector pin is connected to Check the resistance of the warning
battery voltage. device.
A7 Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
customer specific function No 4. to vehicle earth. customer specific function No 4 device.
TCU detected a wrong voltage at Customer specific function No 4 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 4 device to the
short circuit to vehicle earth. TCU.
Connector pin is connected to Check the resistance of the customer
vehicle earth. specific function No 4 device.
A8 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
customer specific function No 4. to battery voltage. customer specific function No 4 device.
TCU detected a wrong voltage at Customer specific function No 4 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 4 device to the
short circuit to battery voltage. TCU.
Connector pin is connected to Check the resistance of the customer
battery voltage. specific function No 4 device.
A9 Open circuit to battery voltage at Cable is defective and has no Check the cable from TCU to the
connection to the TCU. customer specific function No 4 device.
customer specific function No 4.
TCU detected a wrong voltage at Customer specific function No 4 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 4 device to the
open circuit for this output pin. TCU.
Connector has no connection to Check the resistance of the customer
TCU. specific function No 4 device.
AA Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
customer specific function No 5. to vehicle earth. customer specific function No 5 device.

F - 132 9803/4160-12 F - 132

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
AA TCU detected a wrong voltage at Customer specific function No 5 Check the connectors from customer
Cont’d. the output pin, that looks like a device has an internal defect. specific function No 5 device to the
short circuit to vehicle earth. TCU.
Connector pin is connected to Check the resistance of the customer
vehicle earth. specific function No 5 device.
AB Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
customer specific function No 5. to battery voltage. customer specific function No 5 device.
TCU detected a wrong voltage at Customer specific function No 5 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 5 device to the
short circuit to battery voltage. TCU.
Connector pin is connected to Check the resistance of the customer
battery voltage. specific function No 5 device.
AC Open circuit to battery voltage at Cable is defective and has no Check the cable from TCU to the
customer specific function No 5. connection to the TCU. customer specific function No 5 device.
TCU detected a wrong voltage at Customer specific function No 5 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 5 device to the
open circuit for this output pin. TCU.
Connector has no connection to Check the resistance of the customer
TCU. specific function No 5 device.
AD Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
customer specific function No 6. to vehicle earth. customer specific function No 6 device.
TCU detected a wrong voltage at Customer specific function No 6 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 6 device to the
short circuit to vehicle earth. TCU.
Connector pin is connected to Check the resistance of the customer
vehicle earth. specific function No 6 device.
AE Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
customer specific function No 6.
to battery voltage. customer specific function No 6 device.
TCU detected a wrong voltage at Customer specific function No 6 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 6 device to the
short circuit to battery voltage. TCU.
Connector pin is connected to Check the resistance of the customer
battery voltage. specific function No 6 device.
AF Open circuit to battery voltage at Cable is defective and has no Check the cable from TCU to the
customer specific function No 6. connection to the TCU. customer specific function No 6 device.
TCU detected a wrong voltage at Customer specific function No 6 Check the connectors from customer
the output pin, that looks like a device has an internal defect. specific function No 6 device to the
open circuit for this output pin. TCU.
Connector has no connection to Check the resistance of the customer
TCU. specific function No 6 device.
B1 Slippage at clutch K1. Low pressure at clutch K1. Check pressure at clutch K1.

F - 133 9803/4160-12 F - 133

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
B1 TCU calculates a differential speed Low main pressure. Check main pressure in the system.
Cont’d. at closed clutch K1. If this
calculated value is out of range,
TCU interprets this as slipping
clutch.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at output speed Check sensor gap at output speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at output speed sensor.
Replace clutch.
B2 Slippage at clutch K2. Low pressure at clutch K2. Check pressure at clutch K2.
TCU calculates a differential speed Low main pressure. Check main pressure in the system.
at closed clutch K2. If this
calculated value is out of range,
TCU interprets this as slipping
clutch.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at output speed Check sensor gap at output speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at output speed sensor.
Replace clutch.
B3 Slippage at clutch K3. Low pressure at clutch K3. Check pressure at clutch K3.
TCU calculates a differential speed Low main pressure. Check main pressure in the system.
at closed clutch K3. If this
calculated value is out of range,
TCU interprets this as slipping
clutch.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at output speed Check sensor gap at output speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at output speed sensor.
Replace clutch.
B4 Slippage at clutch K4. Low pressure at clutch K4. Check pressure at clutch K4.

F - 134 9803/4160-12 F - 134

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
B4 TCU calculates a differential speed Low main pressure. Check main pressure in the system.
Cont’d. at closed clutch K4. If this
calculated value is out of range,
TCU interprets this as slipping
clutch.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at output speed Check sensor gap at output speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at output speed sensor.
Replace clutch.
B5 Slippage at clutch KV. Low pressure at clutch KV. Check pressure at clutch KV.
TCU calculates a differential speed Low main pressure. Check main pressure in the system.
at closed clutch KV. If this
calculated value is out of range,
TCU interprets this as slipping
clutch.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at turbine speed Check sensor gap at turbine speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at turbine speed sensor.
Replace clutch.
B6 Slippage at clutch KR. Low pressure at clutch KR. Check pressure at clutch KR.
TCU calculates a differential speed Low main pressure. Check main pressure in the system.
at closed clutch KR. If this
calculated value is out of range,
TCU interprets this as slipping
clutch.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at turbine speed Check sensor gap at turbine speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at turbine speed sensor.
Replace clutch.
B7 Overtemp hot sump. Measure temperature of oil in the Cool down machine.
sump is above allowed maximum.

F - 135 9803/4160-12 F - 135

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
B7 TCU measured a temperature in Check oil level.
Cont’d. the oil sump that is over the
allowed threshold.
Check temperature sensor.
B8 Overtemp retarder. Measure temperature of the oil at Cool down machine.
the converter output is above
allowed maximum.
TCU measured a temperature in Check oil level.
the retarder oil that is over the
allowed threshold.
Check temperature sensor.
B9 Overspeed engine.
BA Differential pressure oil filter. Oil filter is polluted. Check oil filter.
TCU measured a voltage at Cable/connector is broken or Check wiring from TCU to differential
differential pressure switch out of cable/connector is contacted to pressure switch.
the allowed range. battery voltage or vehicle earth.
Differential pressure switch is Check differential pressure switch
defective. (measure resistance).
BB Slippage at converter lockup Low pressure at converter lockup Check pressure at converter lockup
clutch. clutch. clutch.
TCU calculates a differential speed Low main pressure. Check main pressure in the system.
at closed converter lockup clutch.
If this calculated value is out of
range, TCU interprets this as
slipping clutch.
Wrong signal at engine speed Check sensor gap at engine speed
sensor. sensor.
Wrong signal at turbine speed Check sensor gap at engine speed
sensor. sensor.
Wrong size sensor gap. Check sensor gap at turbine speed
sensor.
Clutch is defective. Check signal at engine speed sensor.
Check signal at turbine speed sensor.
Replace clutch.
BD Short circuit to vehicle earth at Cable is defective and is contacted Check the cable from TCU to the
engine brake solenoid. to vehicle earth. engine brake solenoid.
TCU detected a wrong voltage at Engine brake solenoid has an Check the connectors from engine
the output pin, that looks like a internal defect. brake solenoid to the TCU.
short circuit to vehicle earth.
Connector pin is connected to Check the resistance of the engine
vehicle earth. brake solenoid.
BE Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the
engine brake solenoid. to battery voltage. engine brake solenoid.

F - 136 9803/4160-12 F - 136

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
BE TCU detected a wrong voltage at Engine brake solenoid device has Check the connectors from engine
Cont’d. the output pin, that looks like a an internal defect. brake solenoid to the TCU.
short circuit to battery voltage.
Connector pin is connected to Check the resistance of the engine
battery voltage. brake solenoid.
BF Open circuit to battery voltage at Cable is defective and has no Check the cable from TCU to the
engine brake solenoid. connection to the TCU. engine brake solenoid.
TCU detected a wrong voltage at Engine brake solenoid device has Check the connectors from engine
the output pin, that looks like a an internal defect. brake solenoid to the TCU.
open circuit for this output pin.
Connector has no connection to Check the resistance of the engine
TCU. brake solenoid.
C3 Overtemp converter output. Measure temperature of oil in the Cool down machine.
sump is above allowed maximum.
TCU measured a temperature in Check oil level.
the converter output that is over
the allowed threshold.
Check temperature sensor.
D1 Short circuit to battery voltage at Check cables and connectors to
power supply for sensors. sensors, which are supplied from AU1.
Check the power supply at the pin AU1
(should be approx. 5V).
D2 Short circuit to earth at power Check cables and connectors to
supply for sensors. sensors, which are supplied from AU1.
Check the power supply at the pin AU1
(should be approx. 5V).
D3 Low voltage at battery. Check power supply battery.
Measured voltage at power supply Check cables from batteries to TCU.
is lower than 10V (12V device),
lower than 18V (24V device).
Check connectors from batteries to
TCU.
D4 High power at battery. Check power supply battery.
Measured voltage at power supply Check cables from batteries to TCU.
is higher than 18V (12V device),
higher than 32.5V (24V device).
Check connectors from batteries to
TCU.
D5 Error at valve power supply VPS1. Cable or connectors are defective Check fuse.
and are contacted to battery
voltage.

F - 137 9803/4160-12 F - 137

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
D5 TCU switched on VPS1 and Cable or connectors are defective Check cables from gearbox to TCU.
Cont’d. measured VPS1 is off or TCU and are contacted to vehicle earth.
switched off VPS1 and measured
VPS1 is still on.
Permanent power supply KL30 Check connectors from gearbox to
missing. TCU.
TCU has an internal defect. Replace TCU.
D6 Error at valve power supply VPS2. Cable or connectors are defective Check fuse.
and are contacted to battery
voltage.
TCU switched on VPS2 and Cable or connectors are defective Check cables from gearbox to TCU.
measured VPS2 is off or TCU and are contacted to vehicle earth.
switched off VPS2 and measured
VPS2 is still on.
Permanent power supply KL30 Check connectors from gearbox to
missing. TCU.
TCU has an internal defect. Replace TCU.
E3 Short circuit to battery voltage at Cable or connectors are defective Check cables from TCU to the display.
display output. and are contacted to battery
voltage.
TCU sends data to the display and display has an internal defect. Check the connectors at the display.
measures a high voltage level on
the connector.
Change display.
E4 Short circuit to vehicle earth at Cable or connectors are defective Check cables from TCU to the display.
display output. and are contacted to vehicle earth.
TCU sends data to the display and display has an internal defect. Check the connectors at the display.
measures a high voltage level on
the connector.
Change display.
E5 DISPID1 Timeout. Interference on CAN-Bus. Check display controller.
Timeout of CAN-message CAN wire/connector is broken. Check wire of CAN-Bus.
DISPID1 from display controller.
CAN wire/connector is defective Check cable to display controller.
and has contact to vehicle earth or
battery voltage.
E6 Illegal ID request via CAN.
F1 General EEPROM fault. TCU is defective. Replace TCU.
TCU can’t read non volatile
memory

F - 138 9803/4160-12 F - 138

 Section F - Transmission
Fault Finding
Fault Codes (4WG-160/190/210)

Fault Fault Possible Cause Action

Code
F2 Configuration lost. interference during saving data on Reprogramme the correct configuration
non volatile memory. for the vehicle (e.g. with cluster
controller).
TCU has lost the correct TCU is brand new or from another
configuration and can’t control the vehicle.
transmission.
F3 Application error. Something in the application is Replace TCU.
wrong.
Something in the application is
wrong.
F5 Clutch failure. One of the AEB values is out of Check clutch.
limit.
AEB was not able to adjust clutch
filling parameters
F6 Clutch adjustment data lost or inch interference during saving data on Execute AEB.
pedal calibration data lost non volatile memory.
TCU was not able to read correct TCU is brand new or from another
clutch adjustment parameters vehicle.

F - 139 9803/4160-12 F - 139

 Section F - Transmission

Service Procedures
Electronic Monitoring System (EMS) Display Panel

Details of the EMS Display Panel and the set-up

procedures can be found in Section C - Electrics.

Details of the EMS displayed fault codes relating to the

transmission can be found in Fault Finding ( F-108).

F - 140 9803/4160-12 F - 140

 Section F - Transmission

Removal and Replacement

Replacement

Replacement of Loader Arm Control

Transmission Dump and Kickdown
Switches
1 Prise the top off the Loader Arm Control lever using a
fine bladed screwdriver or knife.

2 Disconnect connector from the rear of the switch.

3 Depress tabs 1-A on the switch and press switch out

through the Control Lever.

Note: It is advisable to check the suspect switch at this

stage to rule out the possibility of a defective harness
before reassembling the Control Lever.

4 Assembly is the reverse of the dismantling procedure.

Replacement of Wiring to Kick down and

Transmission Dump Switches
1 Remove switch as detailed in steps 1 - 3 above.

2 Remove the instrument panel to access connector.

3 Remove the connector, making a note of the

respective positions. Cut the wires close to the
connector. Fig 1.

4 Draw the wires through the top of the control lever.

5 Feed new wire through aperture for switch 1-B and

out through aperture 1-C.

6 Strip sleeving from last 10 mm of wire. Use special

tool to fit connector to end of wires.

7 Mate connector to instrument cluster connector.

8 Refit cap on Loader Arm Control Lever.

F - 141 9803/4160-12 F - 141

 Section F - Transmission
Removal and Replacement
Replacement

Removal and Replacement of Control

Lever
1 Prise out centre of steering wheel 2-D using a fine
bladed screwdriver.

2 Remove steering wheel securing nut 2-E and

withdraw steering wheel.

3 Release the two column cover securing bolts, 2-F and

remove column cover 2-G.

4 Disconnect connector 2-SE and gently pull the control

lever sideways to clear the locating spigot, 2-H from
the steering column.

5 Assembly is reverse of removal procedure.

Fig 2.

F - 142 9803/4160-12 F - 142

 Section F - Transmission

Propshafts
Basic Operation

Removing and Replacing

When Removing

Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal.

When Replacing

Upon reassembly, after lubricating sliding joints with JCB

HP Grease, align the shafts against identification marks
previously made or, in the case of a shaft being renewed,
use the manufacturers alignment markings.

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

Retaining straps 1-B stretch with use, therefore these

straps must always be replaced with new ones.

Fig 2.

Table 1. Torque Settings

Item Nm kgf m lbf ft
A 75 - 85 7.7 - 8.7 55 - 63

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

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

Fig 1.

The propshafts must have both ends exactly on the same

plane as shown at 2-X. The yokes must not be at right
angles as at 2-Y or at an intermediate angle as at 2-Z.

F - 143 9803/4160-12 F - 143

 Section F - Transmission

Axles
Front Axle

Raise the loader arms and fit the safety strut. Replacement

!MWARNING For assembly the removal sequence should be reversed.

A raised and badly supported machine can fall on you. Refit the road wheels and carry out wheelnut tightness
Position the machine on a firm, level surface before check.
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics Bleed the brake system.
or jacks to support the machine when working under
it. Check the axle and hubs are filled to the correct level with
the appropriate oil, see Section 3 - Routine Maintenance
Disconnect the battery, to prevent the engine being for recommended oil.
started while you are beneath the machine.
GEN-1-1 Table 1. Torque Settings
Item Nm kgf m lbf ft
Removal A 785 80 579
Raise and support the front end of the machine. Remove
the front road wheels.

Disconnect the brake hose at the axle. Blank exposed

connections.

Disconnect front propshaft at axle yoke.

Support the axle on a trolley jack at the point of balance.

Remove nuts and bolts securing axle.

Remove the axle.

If dismantling of the axle is to be carried out, drain the axle

as detailed in Section 3 - Routine Maintenance.

F - 144 9803/4160-12 F - 144

 Section F - Transmission
Axles
Rear Axle

Rear Axle

Fig 1.

Raise the loader arms and fit the safety strut. Remove rear thrust ring 1-5 to release seal and expose
thrust washers. Remove thrust washers 1-6.
!MWARNING At the front of the axle, remove six bolts 1-9 from the front
A raised and badly supported machine can fall on you. of the axle and remove the front seal housing 1-3 and front
Position the machine on a firm, level surface before seal 1-7.
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics Fit a M24 bolt into the tapped hole in the centre of the rear
or jacks to support the machine when working under trunnion mounting 1-4 and pull out the trunnion mounting.
it.
Remove rear seal 1-8 and front thrust ring 1-5.
Disconnect the battery, to prevent the engine being
started while you are beneath the machine. Using bolts in the three tapped holes in the trunnion spigot
GEN-1-1 1-2, jack off the trunnion spigot.

Removal Lift the rear of the machine, tipping the front of the axle
upwards, at the same time manoeuvring the axle
Note: Removal of the rear axle requires lifting gear rearwards. Support the front of the axle as it disengages
capable of lifting the weight of the machine (7.5 tonnes). from the frame.

Raise and support the rear end of the machine. If dismantling of the axle is to be carried out, drain the axle
as detailed in Section 3 - Routine Maintenance.
Disconnect the brake hose from the top of the axle. Blank
exposed connections. Replacement
Disconnect rear propshaft at axle yoke. Replacement is generally a reversal of removal, noting the
following points.
Remove six bolts 1-10 and washers 1-11 from the rear of
the axle. Lubricate seals 1-7 and 1-8 and front and rear trunnion
bearings 1-1 before fitting.

F - 145 9803/4160-12 F - 145

 Section F - Transmission
Axles
Rear Axle
Fit bolts 1-9 loosely initially until rear trunnion mounting,
thrust rings, seals and thrust washer are assembled in
position.

Use JCB Lock and Seal on bolts 1-9 and 1-10.

Check axle oscillation is free.

Torque tighten all bolts.

Bleed the brake system.

Check the axle and hubs are filled to the correct level with
the appropriate oil, see Section 3 - Routine Maintenance
for recommended oil.

Table 2. Torque Settings

Item Nm kgf m lbf ft
9 315 32 233
10 335 34.2 247

F - 146 9803/4160-12 F - 146

 Section F - Transmission
Axles
Rear Axle - Heavy Duty

Rear Axle - Heavy Duty

!MWARNING !MWARNING
A raised and badly supported machine can fall on you. Lifting Equipment
Position the machine on a firm, level surface before You can be injured if you use faulty lifting equipment.
raising one end. Ensure the other end is securely Make sure that lifting equipment is in good condition.
chocked. Do not rely solely on the machine hydraulics Make sure that lifting tackle complies with all local
or jacks to support the machine when working under regulations and is suitable for the job. Make sure that
it. lifting equipment is strong enough for the job.
INT-1-3-7
Disconnect the battery, to prevent the engine being
started while you are beneath the machine. 3 Raise and support the rear of the machine.
GEN-1-1
4 Disconnect the remote grease hoses from the front
Important: The lifting equipment required to carry out this and rear trunnions.
procedure, MUST be capable of lifting and holding the
weight of the rear of the machine, approximately 8 tonnes. 5 Disconnect the brake hose from the axle to the
Likewise any stands or axle blocks intended for use as a chassis. Blank off the exposed connections.
part of this procedure MUST also be capable of holding
this weight. 6 Remove the bolts 13 complete with washers 11 from
the end cover 14, and remove the end cover.
Removal
7 Remove the thrust washer 6 from the rear face of the
Fig 2. ( F-150). trunnion 4.

1 Park the machine on firm level ground. Apply the park 8 Disconnect the propshaft from the axle pinion yoke.
brake and set the transmission to neutral. Chock both
side of both front wheels. Raise the loader arms and 9 Remove the six bolts 9 from the front trunnion seal
install the safety strut as described in Section 3 - housing 3 and remove the housing.
Routine Maintenance
10 Using suitable equipment, support the weight of the
2 Stop the engine and remove the starter key to prevent rear axle beam.
the machine being started whilst you are working on
it. 11 Screw three bolts into the tapped extraction holes in
the front trunnion bearing housing assembly 2, and
extract the assembly from the front chassis beam.
!MCAUTION
Lifting the Machine 12 Remove the rear trunnion securing bolts 10. Screw a
When lifting the machine using the mainframe lifting M24 into the tapped hole in the centre of the rear
points it is necessary to use a lifting frame to prevent trunnion 4 and withdraw the trunnion.
the chains causing damage to the ROPS/FOPS
structure 13 Lift the rear of the machine, tipping the front of the
axle upwards to clear the front chassis beam while
GEN-9-1
simultaneously manoeuvring the axle rearwards.
Support the front of the axle as it disengages from the
front chassis beam.

14 If dismantling of the axle is to be carried out, remove

the axle from beneath the chassis and secure the
chassis as required. Drain the axle oil as detailed in

F - 147 9803/4160-12 F - 147

 Section F - Transmission
Axles
Rear Axle - Heavy Duty
Section 3 - Routine Maintenance and mark or label Replacement
the axle casing to that effect.
Fig 2. ( F-150).
15 If no other procedures (other than the replacement of
the trunnion bushes and seals) are to be carried out 1 Ensure the threaded holes in the axle’s chassis
on the axle, secure the positions of the axle and the beams (front and rear) are clear of any dirt or debris
rear chassis.
2 Using a suitable installation tool, press the trunnion
16 Remove the rear bearing housing assembly 5 from bearing 1a into the rear bearing housing 5, until fully
the rear chassis beam. home.

17 Remove the seal 7a and using a suitable extraction 3 Using a suitable installer, press seal 8 into the recess
tool remove the brass trunnion bearing 1b from the the rear bearing housing 5, until the seal body is flush
front bearing housing 2. Inspect the bearing contact with the outer face. Ensure the seal lip is facing
face and the seal recess for damage. outwards.

18 Remove the seal 7b from the front trunnion seal 4 Apply a light coating of general purpose grease to the
housing 3. Ensure that the seal recess is clean and outer diameter of the sub assembly 5 and press the
undamaged. sub assembly into the rear chassis beam until the
outer face of the assembly is sitting approximately 2
19 Remove the seal 8 and using a suitable extraction mm below the face of the beam. Temporarily secure
tool remove the brass trunnion bearing 1a from the with two diagonally opposed bolts.
rear bearing housing 5. Inspect the bearing contact
face and the seal recess for damage. 5 Apply a generous coating of chassis grease to the
inner diameter and thrust face of the trunnion bearing
20 Inspect the contact faces between the front bearing 1a.
housing 2 and the front chassis beam for signs of
excessive wear or damage.
!MCAUTION
21 Inspect the rear trunnion's mounting recess in the Lifting the Machine
rear of the axle beam for signs of excess wear or When lifting the machine using the mainframe lifting
damage. points it is necessary to use a lifting frame to prevent
the chains causing damage to the ROPS/FOPS
22 Inspect the contact faces between the rear bearing structure
housing 5 and the rear chassis beam for signs of
GEN-9-1
excessive wear or damage.

!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7

6 Using suitable lifting equipment, and with the pinion

nose of the axle tilted upwards, raise the axle (or
lower the chassis) until the nose of the axle’s
differential pinion is engaged through the front
trunnion aperture in the chassis beam. Once the
pinion nose is engaged, adjust the axles position so
that the rear trunnion face is perpendicular.

F - 148 9803/4160-12 F - 148

 Section F - Transmission
Axles
Rear Axle - Heavy Duty
7 Align the axles rear trunnion mounting face centrally hardened washers 11 onto bolts 13, then apply JCB
with the previously installed rear bearing housing 5. threadlocker to the threads of the bolts.

8 Temporarily install two alignment guides to the 20 Place the end cover 14 over the rear bearing housing
threaded holes in the axle. 5 and align the bolt holes. Fit the bolts 13 with
washers 11 through the end cover and the rear
9 Place the rear trunnion 4 onto the installed alignment bearing housing, and screw into the rear chassis
guides and tap home using a soft faced mallet. beam.

10 Fit the securing bolts 10 (8 off), removing the guides 21 Torque tighten the bolts 13 to the specified value.
once the trunnion is secured. At this stage, tighten the Table 3. ( F-149).
bolts just sufficiently to secure the trunnion into its
recess in the axle case. 22 Re-connect the propshaft to the rear axle yoke.
Propshafts ( F-143).
11 Using a suitable installation tool, press the trunnion
bearing 1b into the front trunnion bearing housing 2, 23 Reconnect the remote grease pipes to the front and
until fully home. rear trunnions, then grease as described in Section 3
- Routine Maintenance.
12 Using a suitable installer, press seal 7a into the
recess the front bearing housing 2, until the seal body 24 Reconnect the brake hose to the rear axle, then bleed
is flush with the outer face. Ensure the seal lip is the brake system, as described in Section G -
facing outwards. Brakes.

13 Using a suitable installer, press seal 7b into the Table 3. Torque Settings
recess the front seal housing 3, until the seal body is Item Nm Kgf m lbf ft
flush with the outer face. Ensure the seal lip is facing
9 360 36.72 265
outwards.
10 311 31.72 229
14 Align the front axle trunnion centrally in the front beam 13 259 26.42 191
aperture. Apply a generous coating of chassis grease
to the inner diameter a of the trunnion bearing 1b,
then place the pre-assembled front bearing housing 2
over the trunnion and pull fully home using dummy
bolts 9. Once home remove the dummy bolts.

15 Place the pre-assembled front seal housing 3 over

the front trunnion, ensuring the seal lip is facing
outwards, align the bolt holes with the holes in the
previously installed bearing housing 2.

16 Apply JCB Threadlocker to the threads of the bolts 9,

then fit the bolts through items 2 and 3 and screw into
the chassis beam. Torque tighten to the specified
value. Table 3. ( F-149).

17 Tighten the rear trunnion securing bolts 10 to the

specified value. Table 3. ( F-149).

18 Apply grease to both sides of the thrust washer 6 and

position onto the rear trunnion 4.

19 Remove the two temporary bolts securing the rear

bearing housing 5 to the rear chassis beam. Fit

F - 149 9803/4160-12 F - 149

 Section F - Transmission
Axles
Rear Axle - Heavy Duty

Fig 2. Heavy Duty Axle Components

F - 150 9803/4160-12 F - 150

 Section F - Transmission
Axles
Hub and Driveshaft

F - 151 9803/4160-12 F - 151

 Section F - Transmission
Axles
Hub and Driveshaft

Dismantling
1 If not already done, drain the oil from the axle and
hub.

2 Remove six screws 3-8 and, using the three tapped

holes provided, use screws to pull off cover 3-1.
Remove and discard O ring 3-2.

3 Pull out axle shaft backing plate 3-3 using puller

screw.

4 Remove screws 3-4 and, suitably supporting side

gear carrier 3-5, pry carrier from wheel hub 3-31.

5 Remove lockring 3-15 retaining sun gear 3-14 on

driveshaft and pull out sun gear.

6 Remove disk carrier hub 3-16 together with thrust

washer 3-27 resting against wheel hub sleeve.

7 Remove solid and lined brake disks 3-17, 3-18.

8 Remove driveshaft.
Fig 4.
9 Pull out lockring 3-26 securing ring nut lock plates 3-
24. Remove lock plates. 11 Remove ring nut 3-25 from sleeve 3-38.

10 Install the spring retainer 4-A (Part No. TBA) secured 12 Remove pressure plate 3-21 with brake return
through the three tapped holes in the disk pressure springs 3-22 together with their retainers 3-23, spring
plate 4-21 to compress brake return spring 4-22 (3 in clips 3-47 and pins 3-46.
each hub) and allow ring nut 4-25 to be removed.
13 Suitably support wheel hub 3-31 and pull out ring gear
unit 3-30 and support 3-29.

14 Pick up the six rods 3-19 located in corresponding

seats on ring gear support 3-29.

15 Pry off lockring 3-20 from ring gear 3-30 by using a

suitable screwdriver.

16 Disassemble ring gear support 3-29 from ring gear 3-

30.

17 Should replacement of outer wheel bearing 3-28

inner race be necessary, the bearing may be removed
by a suitable puller or by a remover that can be
inserted in the holes of ring gear support 3-29.

18 Remove brake unit spring retainer 4-A, disassemble

spring 4-22, retaining cup 3-23 and pressure plate 4-
21.

F - 152 9803/4160-12 F - 152

 Section F - Transmission
Axles
Hub and Driveshaft

!MWARNING Assembly
If it is necessary to force out the piston, use only 1 Fit outer races of wheel inner and outer bearings 3-36
gentle pressure, ensuring that adequate safety and 3-28 into wheel hub 3-31, ensuring that they are
precautions are taken. Severe injury can be caused by correctly seated. Position inner race with roller cage
a piston being released suddenly. of wheel inner side bearing 3-36 before fitting lip seal
BRAK-8-4 3-37.

19 Remove brake actuating piston 3-34 from wheel hub 2 Lubricate and fit a new O-ring 3-13.
sleeve 3-38 by using compressed air through brake
oil ducting. 3 Suitably support wheel hub 3-31 to prevent damage
to seals and fit inner race of wheel inner bearing 3-36
20 Remove and discard the two O rings 3-33 and 3-35 in onto sleeve 3-38.
corresponding seats on brake actuating piston.
4 Lubricate and fit new O-rings 3-33 and 3-35 on piston
21 Pull out the complete wheel hub 3-31. Remove and 3-34, insert the piston onto wheel hub sleeve 3-38.
discard O-ring 3-13.
5 Press inner race of wheel outer bearing 3-28 on to
22 Pry off seal 3-37 from wheel hub and remove inner ring gear support 3-29, applying gentle heating if
race with roller cage of inner wheel bearing 3-36. necessary; then mount support 3-29 in ring gear 3-30
and secure by lockring 3-20.
23 Using a suitable press, press out outer races of outer
and inner wheel bearings 3-28 and 3-36 from hub 3- Note: When heating bearings, use heating plates, oven or
31. an oil bath. Never heat parts by using a torch.

24 Should sleeve 3-38 be damaged, it can be removed 6 Mount ring gear and support unit 3-30 and 29 on
by undoing fixing screws 3-41. At reassembly, smear sleeve 3-38.
recommended sealing compound (see Section 1 -
Service Consumables) on axle case joining flange 7 Fit the six rods 3-19 in their seats on ring gear support
and tighten screws with torque of 60 da Nm (61.2 kgf 3-29.
m, 444 lbf ft).
8 Install the spring retainer (see Fig 4. ( F-152) in
25 Mark side gear pins 3-6, accompanying components Dismantling ( F-152)) and compress springs 3-
and seats for identification of original position at 22 (3 off) with relevant cup 3-23, spring clips and pins
reassembly. with the pressure plate 3-21.

26 Arrange side gear carrier 3-5 on wooden blocks and, 9 Mount the pressure plate-spring assembly on ring
using a suitable press, push out pins 3-6. gear support 3-29.

27 Pick up all needle rollers 3-10, 3-11. 10 Screw ring nut 3-25 on wheel hub sleeve 3-38 by
hand. Tighten ring nut 3-25 using an accurately fitting
Note: It is important to keep matched needle rollers and wrench so as to reach the prescribed pre-load for
thrust washers 3-9 with corresponding pin 3-6, because of wheel bearings, corresponding to a revolving torque
predetermined assembly tolerance limits. of 2.5 to 3.5 da Nm, checking alignment for the lock
plates 3-24.
28 Remove side gears 3-12 and corresponding thrust
washers. Note: To prevent wrong recording of torque values, it is
advisable to seat bearing properly before checks by
revolving the wheel hub repeatedly.

11 Remove the spring retainer.

F - 153 9803/4160-12 F - 153

 Section F - Transmission
Axles
Hub and Driveshaft
12 Insert lock plates 3-24 securing ring nut and fit
lockring 3-26.

13 Calculate the space available 7-X to form the disk

pack as follows:

a Record depth 5-A from seating surface of side

gear carrier on wheel hub to outer edge of ring
gear.

b Record depth 5-B from ring gear outer edge to

brake pressure plate. Subtract the value recorded
from value 5-A recorded on previous step, identify
it as D.

i.e. A - B = D

Fig 6.

Fig 5.
Fig 7.
c Record depth 6-C from disk reaction face to outer
14 Form the disk pack. Compute the thickness required
edge of side gear carrier.
as follows:
d Subtract 6-C from value D previously calculated.
a Add total thickness of all disks, solid + lined ones.
Call this E.
i.e. D - C = X
b Add 1mm for each disk. Call the total F.

i.e. Required disk pack thickness = E + F

E + F should be within  0.25 mm of dimension 7-

X calculated in Step 13d.

F - 154 9803/4160-12 F - 154

 Section F - Transmission
Axles
Hub and Driveshaft
15 Arrange the three side gears 3-12 in their seats in
side gear carrier 3-5.

Note: Two rows of needle rollers of the same selection

class should be used for replacement in each single side
gear pin.

16 Insert outer thrust washers 3-9, smear pin lower

portion (head end) with grease and position the first
row of needle rollers 3-10, fit spacers 3-11, smear pin
upper portion with grease and position the second
row of needle rollers 3-10.

17 Position inner thrust washers 3-40 of side gear on

side gear carrier and align holes.

18 Insert and force fit complete pins 3-6, avoiding any

bump or knock that could cause roller fall.

19 Insert driveshaft.

20 Insert thrust washer 3-50.

21 Mount disk carrier hub 3-16 on driveshaft.

22 Mount alternately solid disks 3-18 and lined disks 3-

17.

Note: Insert a solid disk (outer teeth) facing the pressure

plate 3-21.

23 Insert sun gear 3-14 and secure with lockring 3-15.

24 Mount the side gear carrier assembly 3-5 on side gear

unit and secure on wheel hub 3-31, tightening fixing
screws to a torque of 7 da Nm (7.1 kgf m, 51.8 lbf ft).

25 Force fit wheel shaft backing plate 3-3.

26 Lubricate and fit O-ring 3-2.

27 Rotate and align pins 3-6 to allow mounting of cover

3-1. Fit side final drive cover 3-1. The cover locks the
pins, preventing them rotating.

28 Smear fixing screws 3-8 with sealing compound, then

tighten with a torque of 3.5 da Nm (3.6 kgf m, 25.9 lbf
ft).

F - 155 9803/4160-12 F - 155

 Section F - Transmission
Axles
Drive Head

F - 156 9803/4160-12 F - 156

 Section F - Transmission
Axles
Drive Head

Overhauling Pinion Bearing Support

Dismantling

F - 157 9803/4160-12 F - 157

 Section F - Transmission
Axles
Drive Head

Pinion Depth

Fig 9.

Note: See Crown Wheel and Pinion ( F-163) for

general guidance on crown wheel and pinion adjustment. 
Some dimensions should be recorded before starting
reassembly of the bevel pinion to determine the thickness
of the spacer to be fitted between the inner (underhead)
pinion bearing and the backing of relevant seat in
differential support.

Record the dimension 9A from the crown wheel axis to the

seat of the inner (underhead) pinion bearing.

The simplest way to achieve this is by positioning a

reference tube 10T across the differential bearing seats as
shown Fig 10. ( F-158), then measure and record
dimension 10a. Add to this the radius of the differential
bearing 10b to produce the required overall dimension A.

e.g.: Table 4. Examples - Dimension ‘A’ ( F-159). Fig 10.

F - 158 9803/4160-12 F - 158

 Section F - Transmission
Axles
Drive Head
Table 4. Examples - Dimension ‘A’ Therefore using our case:
PR 12 Axle
A = Measured distance (a) + Bearing Radius (b) PR 12 Axle
A = 162.6 + 62.5 = 225.1 mm S=A-B-D
S = 225.1 - 183.9 - 37.00 = 4.2 mm
PR 10 Axle PR 10 Axle
A = Measured distance (a) + Bearing Radius (b) S=A-B-D
A = 144.1 + 62.5 = 206.6 mm S = 206.6 - 168.4 - 34.1 = 4.1 mm

Each bevel pinion head face is marked with a number 9X Increase the calculated value of S by 0.05 mm, to provide
suffixed by a + or - symbol. the required bearing pre-load. Then round the value up or
down to the nearest tenth of a millimetre to give the
This value, expressed in units of 0.1 mm, indicates the required shim value.
deviation from the theoretical pinion underhead to crown
wheel axis dimension B. e.g.:

i.e.: - 1 = - 0.1 mm. 4.02 rounded down to= 4 mm.

Consequently, the true distance 9B will be: 3.88 rounded up to = 3.9 mm.

B = Theoretical distance ± deviation.

Example: using the theoretical figures for PR 10:
e.g.: (all dimensions in millimetres)
Crown wheel axis to bearing seat distance 9A 206.6
PR 12 Axle Theoretical distance gear axis/pinion underhead 168.5
B = Theoretical pinion dimension ± deviation Value 9X, given as -1 -0.1
B = 184.00 - 0.10 = 183.90 mm True distance 9B = 168.5 - 0.1 = 168.4
Thickness of pinion head bearing 9D 34.10
PR 10 Axle
B = Theoretical pinion dimension ± deviation Thickness of shim 9S = A - B - D

B = 168.50 - 0.10 = 168.40 mm

9S = 206.6 - 168.4 - 34.10 = 4.1
Measure the total width 9D of pinion underhead bearing. Increase by 0.05 = 4.15

e.g.: Thickness of shim required = 4.2 mm.

PR 12 Axle
D = 37.00 mm
PR 10 Axle
D = 34.10 mm

Determine the thickness of shim 9S required to give the

correct axial position of the bevel pinion:

S = A - B - D.

F - 159 9803/4160-12 F - 159

 Section F - Transmission
Axles
Drive Head
Reference Measurement

A final measurement needs to be taken before the pinion

nose support bearing 8-8 is fitted. This measurement will
enable the verification of the pinion’s position prior to the
fitment of the crown wheel.

Note: Failure to carry out the verification check, may result

in the differential assembly having to be completely
disassembled to correct the pinion’s position.

Place the pinion nose down on a measuring block.

Measure and record the pinion head height (H) as shown,
Fig 11. ( F-160).

Fig 11.

Examples of Pinion Height

PR 12 Axle
H = 82.00 mm
PR 10 Axle
H = 78.50 mm

F - 160 9803/4160-12 F - 160

 Section F - Transmission
Axles
Drive Head

Assembly Important: The dimension measured as H has to result in

a figure 0.05mm less than the theoretical computation (E)
1 Press fit inner race of inner (underhead) pinion because there is no bearing pre-load.
bearing 8-18 on pinion, using heat if required.
Important: If the recorded dimension H, allowing for the
Note: When heating bearings, use heating plates, oven or pre-load deviation, does not result in the theoretical
an oil bath. Never heat parts by using a torch. computation E then the Pinion Depth procedure needs to
be re-applied as the calculated shim thickness is incorrect.
2 Position shim 8-19, computed as in Pinion
Depth ( F-158), in its seat and press fit outer races 4 Fit spacer 8-20 on pinion together with shims 8-21 for
of inner pinion bearing 8-18 and outer pinion bearing bearing pre-load adjustment, then mount inner race
8-17. of pinion outer bearing 8-17.

3 Position the pinion on its seat in the differential Note: To facilitate proper pre-load computation, it is
housing. Position a reference tube T across the advisable to mount as many shims as required to warrant
differential bearing seats as shown Fig a pinion end play and not pre-load (which could be
12. ( F-161), and, measure and record dimension excessive) on bearings.
E.
5 Fit drive flange 8-13 on pinion 8-16, clamp drive
flange 8-13 to prevent pinion turning and tighten nut
8-12 with a torque of 57 to 63 da Nm (58.2 to 64.3 kgf
 m, 422 to 467 lbf ft). Back up reaction screw from
pinion.

6 Check pinion end play by mean of a dial gauge; then

disassemble parts and change shims so as to
eliminate all end play and reach the intended pre-
load.

7 Reassemble components, noting that proper pre-load

of bearing corresponds to a revolving torque (no seal
installed) of 0.20 to 0.40 da Nm (0.2 to 0.4 kgf m, 1.5
to 3 lbf ft).

8 When the prescribed pre-load of bearings has been

reached, remove drive flange 8-13 and fit lip seal 8-
15 in its seat. Remount drive flange again and tighten
Fig 12. as specified above.

Calculate pinion’s axial position as follows: 9 Position differential assembly with crown wheel on
support 8-9.
E = B - 62.50 - H
10 Insert support 8-7 of bearing 8-8 whilst differential is
lowered and tighten fixing screw 8-6 with a torque of
Examples of Pinion Axial Position Calculation 33 da Nm (33.7 kgf m, 244 lbf ft).
Using our case figures
PR 12 Axle 11 Fit ring nuts 8-3 and adjust backlash temporarily.

E = 183.9 - 62.5 - 82.00 = 39.4 mm 12 Mount caps 8-4, taking care not to invert position, fit
PR 10 Axle and tighten screws 8-5 to a torque of 33 Nm (33.7 kgf
m, 244 lbf ft). Check differential end play using a dial
E = 168.4 - 62.5 - 78.5 = 27.4 mm
gauge.

F - 161 9803/4160-12 F - 161

 Section F - Transmission
Axles
Drive Head
13 Screw in one of the ring nuts 8-3 so that a notch aligns PR10 PR12
against the slot of lock plate and screw up the
opposite ring nut to eliminate end play. (22.4 kgf m, 163 lbf ft) (11.8 kgf m, 85 lbf ft)

14 When this condition has been reached, apply bearing Note: Check the axle plate to identify which axle type is
pre-load by screwing in ring nut one more notch. fitted.

15 Position a dial gauge perpendicular to the ring gear 8-

31 tooth as shown at 13A and check that, with pinion
steady, backlash is 0.17 mm to 0.28 mm (0.006 -
0.010 in), otherwise rotate both ring nuts 8-3,
displacing them the same number of notches and
moving the ring gear nearer to the pinion if backlash
is excessive or moving it away if the backlash is less
than specified.

Fig 13.

16 Check gears for correct meshing (see

Adjustment ( F-163)).

17 Fit spring pins 8-2 to lock differential ring nuts. Make

two lock notches on collar of pinion ring nut 8-12.

18 Apply sealing compound to bevel ring gear deflection

plunger 8-10, then screw in up to contact; turn back
by about 90° to leave the required clearance and
tighten locknut.

19 Thoroughly clean matching surfaces, apply sealing

compound and mount differential unit on axle case.
Insert and tighten screws 8-1 with a torque from the
table below:

PR10 PR12
22 da Nm 11.5 da Nm

F - 162 9803/4160-12 F - 162

 Section F - Transmission
Axles
Crown Wheel and Pinion

Crown Wheel and Pinion

Adjustment Incorrect Pattern - High Contact

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. After every repair, check the
markings to verify settings.

Correct Pattern

Fig 16. Concave Side

Fig 14. Concave Side

Fig 17. Convex Side

High Contact

Increase the shim thickness.

Repeat the procedure on Pinion Depth ( F-158) to

determine the correct shim thickness.
Fig 15. Convex Side

F - 163 9803/4160-12 F - 163

 Section F - Transmission
Axles
Crown Wheel and Pinion
Decrease the shim thickness.

Repeat the procedure on Pinion Depth ( F-158) to

determine the correct shim thickness.

Fig 18.

Incorrect Pattern - Low Contact

Fig 21.

Fig 19. Concave Side

Fig 20. Convex Side

Low Contact

F - 164 9803/4160-12 F - 164

 Section F - Transmission
Axles
Limited Slip Differential Unit

Limited Slip Differential Unit

Fig 22.

F - 165 9803/4160-12 F - 165

 Section F - Transmission
Axles
Limited Slip Differential Unit

Dismantling e disc 4

1 Match mark differential case halves 22-2 and 22-3. f disc 6 (Fitted with lined face DOWN)

2 Place differential unit with the crown wheel at the Note: Disc 4 has outer lugs. Disc 5 is thin, has internal
bottom. splines and is lined on both faces. Disc 6 is thick, has
internal splines and is lined on one face.
3 Remove bolts 22-1 and separate differential case
halves 22-2 and 22-3. 5 Fit sun gear 22-7, take care to mesh splines with
discs 22-5 and 22-6.
4 Remove discs 22-4, 22-5 and 22-6 and sun gear 22-
7. 6 Fit spider assembly 22-10 complete with side gears
22-9 and thrust washers 22-8.
5 Remove spider assembly 22-10 complete with side
gears 22-9 and thrust washers 22-8. 7 Fit sun gear 22-7.

6 Remove discs 22-4, 22-5 and 22-6 and sun gear 22- 8 Place disc pack on to sun gear 22-7. The disc pack is
7. made up as follows:

7 Using a suitable puller, remove bearings 22-13. a disc 6 (Fitted with lined face UP)

Note: Bearings 22-13 should only be removed if damaged b disc 4

or worn.
c disc 5
8 Clamp crown wheel 22-12 in a vice fitted with soft
caps and remove screws 22-11 securing crown wheel d disc 4
22-12 to half-case 22-2.
e disc 5
Assembly f disc 4
1 If necessary, fit new bearings 22-13.
Note: Align outer lugs of discs 22-4.
Note: When heating bearings, use heating plates, oven or
9 Fit case-half 22-3, take care to mesh outer lugs of
an oil bath. Never heat parts by using a torch.
discs 22-4.
2 Secure crown wheel 22-12 onto half-case 22-2 using
Note: Make sure match marks are aligned.
screws 22-11.
10 Fit and torque tighten screws 22-1.
3 Place differential unit with the crown wheel at the
bottom.
11 Check the free play of each disc pack. There must be
a clearance of between 0.05 to 0.1 mm (0.002 to
4 Place disc pack into half-case 22-2. The disc pack is
0.004 in.) for correct operation of the limited slip
made up as follows:
differential.
a disc 4
Check the clearance at two points, 120º apart, as
shown.
b disc 5
Turn the differential unit over and check the clearance
c disc 4
on the second disc pack.
d disc 5

F - 166 9803/4160-12 F - 166

 Section F - Transmission
Axles
Limited Slip Differential Unit
Note: If the clearance is out of limits, dismantle and select
discs 22-4 of different thickness, reassemble and carry out
step 11 again.

Fig 23.

12 Refit differential unit to drive head.

Table 5. Torque Settings

Item Nm kgf m lbf ft
1 113.8 to 122.6 11.5 to 12.5 7.7 to 8.4
11(1) 308.9 to 338.3 31.5 to 34.5 21.1 to 23.2
11 (2) 308.9 to 338.3 31.5 to 34.5 21.1 to 23.2
11 (3) 451.1 to 490.3 46 to 50 30.9 to 33.6

(1) PR10
(2) PR12
(3) PR15

Note: Details of axle type (PR10, 12 or 15) is shown on

axle data plate.

F - 167 9803/4160-12 F - 167

Section G

Brakes
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-11



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section G - Brakes

Page left intentionally blank

G-0 9803/4160-11 G-0

 Section G - Brakes

Contents Page No.

Technical Data
446 (From Serial Number 540000 to 540011) ........................................ G - 1
.......................................................................................................... G - 1
426/436 .................................................................................................. G - 2
.......................................................................................................... G - 2

Brake Circuits
426 To Serial Number 532099, 436 to Serial Number 533691,
446 from Serial No. 540000 to 540011 ................................................... G - 3
426 From Serial Number 532100, 436 from Serial Number 533692 ...... G - 4
436 From Serial Number 534200 (Tier II) ............................................... G - 5

Service Procedures
Service Brakes ....................................................................................... G - 6
System Testing .................................................................................. G - 6
436 from Serial No. 534200 - (Tier II, with Hydraulic
Engine Cooling Fan ........................................................................... G - 8
Brake Pressure Setting ................................................................... G - 10
Bleeding the System ....................................................................... G - 12
System Accumulators ........................................................................... G - 13
Charging the Accumulators ............................................................. G - 13
Parking Brake (Type 1) ......................................................................... G - 14
Adjusting the Parking Brake ............................................................ G - 14
Adjusting the Brake Pads ................................................................ G - 14
Adjusting the Cable Slack ............................................................... G - 15
Renewing the Brake Pads ............................................................... G - 16
Parking Brake (Type 2) ......................................................................... G - 17
Adjusting the Parking Brake ............................................................ G - 17
Adjusting the Cable Slack ............................................................... G - 18
Renewing the Brake Pads ............................................................... G - 20
Park Brake Testing ............................................................................... G - 23
Pre Smoothshift Machines .............................................................. G - 23
Smoothshift Machines ..................................................................... G - 24

Brake Valves
Foot Valve ............................................................................................. G - 25
Removal and Replacement ............................................................. G - 25
Dismantling and Assembly .............................................................. G - 26

Parking Brake
Type 1 ................................................................................................... G - 28
Dismantling and Assembly .............................................................. G - 28
Type 2 ................................................................................................... G - 29
Dismantling ...................................................................................... G - 29
Assembly ......................................................................................... G - 29

G-i G-i
 Section G - Brakes

Contents Page No.

G - ii G - ii
 Section G - Brakes

Technical Data
446 (From Serial Number 540000 to 540011)

Service Brake
Type Oil-Immersed Multi-Plate Disc Actuation
Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators
Location Front and Rear Axle (4 plates per hub)
Control Valve Type Compact

Pressure Regulator Setting

Cut-in Pressure 164 bar 2378 lbf/in2
Cut-out Pressure 200 bar 2900 lbf/in2
Maximum Pressure Differential 36 bar 522 lbf/in2

Service Brake Operating Pressure 80 bar 1160 lbf/in2

Accumulator
Capacity (per circuit) 0.75 litre 1.3 pint
Number (fitted) 4
Accumulator Gas Nitrogen
Pre-charge 57 bar 826 lbf/in2

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

G-1 9803/4160-11 G-1

 Section G - Brakes
Technical Data
426/436

426/436

Service Brake
Type Oil-Immersed Multi-Plate Disc Actuation
Actuation Dual Circuit, Full Hydraulic with compact valve and pressure accumulators
Location Front and Rear Axle (4 plates per hub)
Control Valve Type Compact

Pressure Regulator Setting

Cut-in Pressure 164 bar 2378 lbf/in2
Cut-out Pressure 200 bar 2900 lbf/in2
Maximum Pressure Differential 36 bar 522 lbf/in2

Charge Valve Setting 436 Tier II from Serial No. 534200 (with hydraulic engine cooling fan)
Cut-in Pressure 145 bar 2103 lbf/in2
Cut-out Pressure 180 bar 2611 lbf/in2
Maximum Pressure Differential 35 bar 508 lbf/in2

Service Brake Operating Pressure 80 bar 1160 lbf/in2

Pressure Switch Operating Pressure

Low Pressure Warning on 105 bar 1523 lbf/in2

Accumulator
Capacity (per circuit) 0.75 litre 1.3 pint
Number (fitted) 4
Accumulator Gas Nitrogen
Pre-charge 57 bar 826 lbf/in2

Parking Brake
Type Manually Adjusted Disc, cable operated
Location Front face of transmission

G-2 9803/4160-11 G-2

 Section G - Brakes

Brake Circuits
426 To Serial Number 532099, 436 to Serial Number 533691, 446 from
Serial No. 540000 to 540011

Fig 1.
7 Return Filter/Diffuser
Component Key
T Tank
1 Suction Strainer
2 Engine Driven Gear Pump
3 Brake Valve
4 Accumulators
5 Front Axle Brakes
6 Rear Axle Brakes

G-3 9803/4160-11 G-3

 Section G - Brakes
Brake Circuits
426 From Serial Number 532100, 436 from Serial Number 533692

426 From Serial Number 532100, 436 from Serial Number 533692

Fig 2.

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

G-4 9803/4160-11 G-4

 Section G - Brakes
Brake Circuits
436 From Serial Number 534200 (Tier II)

436 From Serial Number 534200 (Tier II)

Fig 3.

Component Key
1 Suction Strainer
2 Engine Driven Gear Pump and Charge Valve
3 Accumulators
4 Brake Valve
5 Front Axle Brakes
6 Rear Axle Brakes
7 Oil Cooler
8 Return Filter/Diffuser
9 Filler Breather
10 Engine Cooling Fan Hydraulic Motor
T Tank

G-5 9803/4160-11 G-5

 Section G - Brakes

Service Procedures
Service Brakes

System Testing 4 Provided that the Maximum Pressure Differential is

not exceeded, (see Technical Data ( G-1)), the
Pressure Regulator in the brake valve may be
!MWARNING adjusted at 4X to bring the pressures within the above
Before working on the brake system make sure the parameters. If, however, the pressure differential is
machine is on level ground and chock all four wheels. greater than specified, the pressure regulator is faulty
and the brake valve should be renewed.
BRAK-1-4

Stop the engine and operate the service brake pedal

!MDANGER a few times. The accumulator pressure should fall
only slightly with each brake application. If the
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock pressure falls drastically, it is likely that the
accumulators need recharging with nitrogen gas.
must also be fitted if you are carrying out daily checks
Repeat this test for the other brake circuit.
or doing any maintenance work in the articulation
danger zone.
Note: The pressure differential cannot be adjusted.
If the articulation lock is not fitted you could be
crushed between the two parts of the chassis.
GEN-3-1_1

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

Testing the System Pressure (Stored

Accumulator Pressure)
1 Switch off the engine and operate the brake pedal
repeatedly to make sure that all hydraulic pressure
stored in the accumulators is discharged.

2 Disconnect one of the service brake accumulator

hoses from the brake valve. Make up an adaptor to
connect Pressure Test Gauge Kit 892/00253 between
the valve and the accumulator hose.
Fig 4.
3 Switch on the engine and check the gauge reading
which should rise to the Pressure Regulator Cut-out
Pressure. (See Technical Data ( G-1).) Operate
the service brake pedal repeatedly with the engine
running and check that the gauge reading does not
fall below the Pressure Regulator Cut-in Pressure.
(See Technical Data ( G-1))

G-6 9803/4160-11 G-6

 Section G - Brakes
Service Procedures
Service Brakes
Testing the System Pressure (Remote Test Point)

1 Switch off the engine and operate the brake pedal

repeatedly to make sure that all hydraulic pressure
stored in the accumulators is discharged.

2 Connect Pressure Test Gauge Kit 892/00253 to the

remote test point beneath the engine cover.

3 Switch on the engine and check the gauge reading

which should rise to the Pressure Regulator Cut-Out
pressure. (See Technical Data ( G-1)) As soon
as this pressure is reached, the gauge reading will fall
to zero. Record the maximum pressure obtained.

Note: Provided there are no leaks on the system and the

brake pedal is not applied the gauge reading will remain at
zero. Once the systems maximum pressure has been
obtained the pressure regulator valve will discharge the
pump pressure back to the tank. The charged lines
between the brake valve and the accumulators will still
be at full charge pressure. Before attempting to Fig 5.
disconnect any part of the brake system, make sure the
engine is switched off and all the hydraulic pressure is Note: The pressure differential cannot be adjusted.
discharged by repeatedly pressing the brake pedal.
Note: This method of testing the system will not show the
4 Operate the brake pedal a number of times to use the actual pressure drop per application of the brake. If you
pressure stored at the accumulators, until the suspect the depletion of the systems pressure is too rapid,
pressure has dropped sufficiently for the regulator carry out the Testing the System Pressure (Stored
valve to cut in.
Accumulator Pressure) ( G-6) procedure.
5 As the valve cuts in the pressure reading on the
gauge will jump to show the retained system
pressure. Record this pressure.The pressure will
continue to rise until the maximum pressure is
obtained, at which point, the reading on the gauge will
again fall to zero as the regulator valve cuts out.

Note: The pressure reading at step 5 will be the Pressure

Regulator Cut-in pressure. It must not be lower than the
minimum figure given in Technical Data ( G-1).

6 Subtract the figure obtained at step 5 from the

pressure regulator Cut-out pressure figure obtained
at step 3. Provided that the Maximum Pressure
Differential is not exceeded, (see Technical
Data ( G-1)), the pressure regulator in the brake
valve may be adjusted at 5X to bring the pressures
within the required parameters. If, however, the
pressure differential is greater than specified, the
pressure regulator is faulty and the brake valve
should be renewed.

G-7 9803/4160-11 G-7

 Section G - Brakes
Service Procedures
Service Brakes

436 from Serial No. 534200 - (Tier II, with Key:

Hydraulic Engine Cooling Fan A Brake Test Point
B Hydraulic Engine Fan Test Point
!MWARNING C Low Pressure Switch
Before working on the brake system make sure the
machine is on level ground and chock all four wheels. 1 Switch off the engine and operate the brake pedal
BRAK-1-4 repeatedly to make sure that all the hydraulic
pressure stored in the accumulators is discharged.
!MDANGER 2 Connect a 400 bar test gauge to the test point 6A on
Make sure the articulation safety lock is fitted before the combined engine driven gear pump and charge
transporting the machine. The articulation safety lock valve.
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation 3 Switch on the engine and check that the gauge
danger zone. reading rises to the Charge Valve Cut-out Pressure.
(See Technical Data ( G-1))
If the articulation lock is not fitted you could be
crushed between the two parts of the chassis. 4 With the engine running and the maximum charge
GEN-3-1_1 pressure obtained, repeatedly operate the brake
pedal. Check that the pressure is recharged to its
maximum pressure as each stoke of the brake pedal
!MWARNING is applied.
Before disconnecting any part of the brake hydraulic
system, make sure that engine is switched off and Note: There is no noticeable successive reduction in the
hydraulic pressure is fully discharged. system pressure (with each stoke of the brake pedal) until
BRAK-3-1 the Cut-in pressure is reached. The system will start to
recharge after the first full stroke of the pedal.
Testing the System Pressure
5 Fully charge the system.

6 Switch off the engine. Switch the ignition ON. Slowly

and repeatedly operate the brake pedal (apply full
pedal stokes) until the low brake pressure warning
lamp illuminates. Check the pressure reading on the
gauge. (See Technical Data ( G-1) for Low
Pressure Switch operating Pressure)

7 Continue to operate the brake pedal until the

pressure drop-off point is reached. There must be a
Minimum of 5 Full Pressure Strokes Before the
pressure drop off point is reached.

Note: As the brake pedal is repeatedly applied (engine

switched OFF) the stored accumulator pressure is
gradually depleted At a pressure normally below 80 bar,
the stored pressure will be exhausted. At this point the
pressure gauge reading will fall to zero.
Fig 6.
Note: The system charge pressures (cut-in, cut-out
pressures) are pre-set and non-adjustable. If the

G-8 9803/4160-11 G-8

 Section G - Brakes
Service Procedures
Service Brakes
pressures are found to be outside the given parameters,
the charge valve will need to be replaced.

Note: If you suspect the pressure depletion per full stoke

of the brake pedal is excessive, or the minimum number of
strokes before drop-off are not obtained, check the
accumulator charge pressures and where necessary
correct, (See Charging the Accumulators ( G-13))
before retesting the brake system.

G-9 9803/4160-11 G-9

 Section G - Brakes
Service Procedures
Service Brakes

Brake Pressure Setting 5 Without changing the adjustment, disconnect the

push rod from the pedal. Apply heat shrink sleeving
Note: Use the following procedure to test and set the brake as shown at 7B.
pressure if the heat shrink sleeving 7A, 7B has been
removed. 6 Re-check the pressure. Remove the test point and
gauge.

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

If the articulation lock is not fitted you could be

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

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

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

1 With the brake pedal fully up, check that there is a

little free play between the brake push rod and the
pedal assembly.

2 With the engine stopped and brake pressure

released, connect a “T” adaptor at point 7C then
connect a suitable pressure gauge (capable of
reading 300 bar).

3 With the brake system operational, depress the brake

pedal until the gauge shows the correct Operating
Pressure. (See Technical Data ( G-1)). With the
pedal held in this position, adjust pedal stop 7D to
contact the pedal. Release and re-operate the pedal
a few times, checking each time that the gauge
reading does not exceed the stated operating
pressure. Tighten the stop locking nut.

4 Apply heat shrink sleeving as shown at 7A.

G - 10 9803/4160-11 G - 10
 Section G - Brakes
Service Procedures
Service Brakes

Fig 7.

G - 11 9803/4160-11 G - 11
 Section G - Brakes
Service Procedures
Service Brakes

Bleeding the System

!MWARNING
Before proceeding with the bleeding procedure it is
important to ensure that the park brake is engaged and
that one pair of wheels is blocked on both sides.
BRAK-1-2

Note: The braking systems are fed from the main hydraulic
system and incorporate brake accumulators. These allow
approximately nine applications of the brakes with the
engine stopped.

Bleed each axle separately as follows:

– Attach a tube to the brake bleed screw, located near

the axle centre. Ensure that the free end of the tube
is immersed in fluid contained in a suitable container.
– Open the brake bleed screw and fully depress the
brake pedal. Hold the pedal fully depressed until air
free fluid flow from the bleed screw.
– Close the brake bleed screw with the pedal fully
depressed.

Repeat the procedure for the rear axle.

Check the hydraulic fluid level.

G - 12 9803/4160-11 G - 12
 Section G - Brakes
Service Procedures
System Accumulators

System Accumulators

Charging the Accumulators

For details on the identification of and charging procedures
for the accumulators, please refer to Section E -
Hydraulics - ACCS - Accumulators.

G - 13 9803/4160-11 G - 13
 Section G - Brakes
Service Procedures
Parking Brake (Type 1)

Parking Brake (Type 1)

Adjusting the Parking Brake Adjusting the Brake Pads

1 Disengage the parking brake (lever horizontal). 1 Turn adjuster 9A anti-clockwise to return pin 9B to the
bottom of the slot.
2 Turn adjuster 8A clockwise, half a turn.
2 Check the pads just touch the disc when the parking
3 Test the parking brake. See Park Brake brake is disengaged (lever horizontal).
Testing ( G-22).
3 If necessary, adjust the pad position by removing split
4 If the brake fails the test, repeat steps 1 to 3. pin 10D and turning nut 10C until the disc is clamped
then back off nut 10C until the pads have a clearance
Note: If after completing the above steps, the parking of 0.5 mm (0.020 in) between the disc and one pad.
brake does not pass the testing procedure. See
Adjusting the Brake Pads ( G-14). 4 Engage the parking brake 3 times and repeat step 2.

5 When adjustment is correct fit new split pin.

Fig 8.

Fig 9.

G - 14 9803/4160-11 G - 14
 Section G - Brakes
Service Procedures
Parking Brake (Type 1)

Adjusting the Cable Slack

1 Loosen locknut 10E and remove shouldered bolt 10G
(at either end of the cable) ensure securing nut and
washer are retained.

2 Screw in the clevis 10F only enough to remove the

cable slack.

3 Refit shouldered bolt 10G and tighten locknut 10E to

27 Nm (19.9 lbf ft).

4 Test the parking brake, see Testing the Parking

Brake.

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

Note: The cable end must not contact lever 10H.

Note: If the brake cannot be adjusted by adjusting the

pads and the cable slack, the cable must be replaced.

Note: When fitting new brake pads adjust the cable length
as necessary.

Fig 10.

G - 15 9803/4160-11 G - 15
 Section G - Brakes
Service Procedures
Parking Brake (Type 1)

Renewing the Brake Pads 4 Remove old brake pads, fit new brake pads 11F.

Renew pads when thickness of friction material is 1.5mm Note: Make sure new brake pads and springs are seated
(0.060 in). correctly.

1 Remove split pin 11A and nut 11B. 5 Refit brake unit 11E and refit bolts 11D. Take care to
fit spacers correctly. Torque tighten bolts to 27 Nm
2 Remove lever arm 11C from spindle and stow out of (19.9 lbf ft).
the way.
6 Refit lever arm 11C as near as 90° to the cable pull as
3 Remove bolts 11D, remove brake unit 11E. Take care possible.
to retain spacers.
7 Adjust the pads. See Adjusting the Brake
Pads ( G-14).

Fig 11.

G - 16 9803/4160-11 G - 16
 Section G - Brakes
Service Procedures
Parking Brake (Type 2)

Parking Brake (Type 2)

Adjusting the Parking Brake

1 Disengage the parking brake (lever horizontal).

2 Turn adjuster 12X clockwise, half a turn.

3 Test the parking brake. See Park Brake

Testing ( G-22).

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

Note: If after completing the above steps, the parking

brake does not pass the testing procedure. See
Adjusting the Brake Pads ( G-14).

Fig 13.

Fig 12.

G - 17 9803/4160-11 G - 17
 Section G - Brakes
Service Procedures
Parking Brake (Type 2)

Adjusting the Cable Slack

1 Parking brake lever without safety catch ( Fig
14. ( G-18)).Turn adjuster 14X anti-clockwise to
return pin 14Y to the bottom of the slot.

2 Parking brake lever with safety catch ( Fig

15. ( G-18)). Turn adjuster 15X anti-clockwise to
return pin 15Y to the bottom of the slot. Make sure
that the lever is fully down against its stop at 15Z.

3 Loosen locknut 16A and remove pin 16B (at either

end of the cable).

4 Screw in the clevis 16C only enough to remove the

cable slack.

5 Refit pin 16B and tighten locknut 16A to 27 Nm (19.9

lbf ft).
Fig 14.
6 Test the parking brake, see Park Brake
Testing ( G-22).

7 If the brake fails the test, repeat steps 1 to 5.

Note: If the brake cannot be adjusted by adjusting the

cable slack, replace the brake pads and/or the brake cable.

Note: Operating arm 16D has three machined holed to

accommodate pin 16B. It is MOST IMPORTANT that pin
16B is fitted ONLY to the CENTRE HOLE.

Note: If the operating arm securing bolt 16E has to be

removed it is MOST IMPORTANT that prior to removing
the operating arm 16D its position on its splined shaft is
carefully marked. The arm MUST be refitted in its
ORIGINAL POSITION. Under NO CIRCUMSTANCES
must the arms position in relation to its shaft be altered in Fig 15.
an attempt to gain additional movement, as this could
cause damage to or failure of the parking brake.

G - 18 9803/4160-11 G - 18
 Section G - Brakes
Service Procedures
Parking Brake (Type 2)

Fig 16.

G - 19 9803/4160-11 G - 19
 Section G - Brakes
Service Procedures
Parking Brake (Type 2)

Renewing the Brake Pads

Renew pads when thickness of friction material is 1mm
(0.039 in).

1 Release brake and disconnect actuator from brake

lever.

2 Slacken one and remove the other brake mounting

bolt 17-1, washer 17-2 and nut 17-3 position brake to
expose brake pads.

3 Use flat bladed screw driver to remove pads 17-4 and

17-5.

Note: Take care when removing pad from the plastic

actuator cover.

4 Place pads in position.

Note: Centre hole in lever side pad snaps over tabs on

actuator cover. Align pad with flat on rotor cover 17-B. If
tabs are broken dab pad adhesive on the back edge of the
pad and press firmly into correct position.

5 Remove pad adhesive from pad compartment in pad

carrier plate 17-A.

6 Apply adhesive along back edge of pad carrier plate

and press into place.

7 Push lever side pad as far as possible into the brake.

8 Position brake over disc, fit mounting bolt 17-1,

washer 17-2 and nut 17-3 and torque both bolts to
119Nm (140 lb ft).

9 Attach cable to lever.

10 Adjust pad gap.

G - 20 9803/4160-11 G - 20
 Section G - Brakes
Service Procedures
Parking Brake (Type 2)

Fig 17.

G - 21 9803/4160-11 G - 21
 Section G - Brakes
Service Procedures
Park Brake Testing

Park Brake Testing

Pre Smoothshift Machines b Reduce the engine speed to idle and set the
forward/ reverse lever (or switch) to neutral.
Note: Pre-Smoothshift machine serial numbers as follows:
426 to Serial No. 532099, 436 to Serial No. 533691 Do not do this test for longer than 20 seconds.

Testing the Parking Brakes 7 Return the parking brake lever to the fully on position
from its partially applied position.

!MWARNING 8 Lower attachment and stop the engine.

Before testing the park brake make sure the area
Note: If the machine moved during the test, see
around the machine is clear of people.
Adjusting the Parking Brake ( G-14). Do not use
2-2-4-5
the machine with faulty brakes.
Test the brake on a level, dry surface. Make sure your seat
If you have any queries concerning this test procedure
belt is securely fastened.
or parking brake adjustment, consult your local JCB
dealer.
1 The attachment should be in the travelling position.

2 Make sure the parking brake is fully engaged. !MWARNING

3 Switch off transmission dump. Do not use a machine with a faulty park brake.
3-2-3-10_2
4 Select 4 on gear selector.
!MWARNING
a Push down hard on the brake pedal and select
forward drive. Non approved modifications to drive ratios, machine
weight or wheel and tyre sizes may adversely affect
Note: An audible alarm will sound and a warning light will the performance of the parking brake.
show when the parking brake is engaged with the machine 3-2-3-11
in forward (F) drive. The alarm will stop when neutral (N)
drive is selected. Parking Brake Transmission Disconnect

b Keep the brake pedal pushed down. When fully engaged, the parking brake electrically
disconnects the transmission drive; this prevents the
5 Move the parking brake lever fractionally forward until machine from being driven with the parking brake on. With
the parking brake warning light is just extinguished. 4 selected, the transmission disconnect is inhibited.

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

6 Release the brake pedal.

a If the machine has not moved, use the accelerator

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

G - 22 9803/4160-11 G - 22
 Section G - Brakes
Service Procedures
Park Brake Testing

Smoothshift Machines a If the machine has not moved, use the accelerator
pedal to gradually increase the engine speed to
Note: Smoothshift machine serial numbers as follows:426 1500rpm. The machine should not move.
to Serial No. 532100, 436 to Serial No. 533692
b Reduce the engine speed to idle and set the
Testing The Parking Brake forward/ reverse lever (or switch) to neutral.

Do not do this test for longer than 20 seconds.

!MWARNING
7 Return the parking brake lever to the fully on position
Before testing the park brake make sure the area
from its partially applied position.
around the machine is clear of people.
2-2-4-5
8 Press SETUP key again to select park brake test off.
Test the brake on a level, dry surface. Make sure your seat
9 Lower attachment and stop the engine.
belt is securely fastened.
Note: If the machine moved during the test, see
1 The attachment should be in the travelling position.
Adjusting the Parking Brake ( G-14). Do not use
the machine with faulty brakes.
2 Make sure the parking brake is fully engaged.
If you have any queries concerning this test procedure
3 Switch off transmission dump.
or parking brake adjustment, consult your local JCB
dealer.
4 Switch off Auto/Manual switch.

a On the EMS press the two arrow keys and the !MWARNING
SETUP key at the same time, to select the AEB
setup menu. Do not use a machine with a faulty park brake.
3-2-3-10_2
b Use the UP or DOWN arrows to select the park
brake test menu. !MWARNING
c Press SETUP key to select park brake test on. Non approved modifications to drive ratios, machine
weight or wheel and tyre sizes may adversely affect
5 Select third gear/range (3). the performance of the parking brake.
3-2-3-11
a Push down hard on the brake pedal and select
forward drive. Parking Brake Transmission Disconnect

Note: An audible alarm will sound and a warning light will When fully engaged, the parking brake electrically
show when the parking brake is engaged with the machine disconnects the transmission drive; this prevents the
in forward (F) drive. The alarm will stop when neutral (N) machine from being driven with the parking brake on.
drive is selected.

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

6 Release the brake pedal.

G - 23 9803/4160-11 G - 23
 Section G - Brakes

Brake Valves
Foot Valve

Removal and Replacement 5 Remove cap screws 18-2 and remove the valve from
the bracket.

!MDANGER Replacement
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock 1 Refit the valve by reversing the removal sequence.
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation 2 When connecting the foot pedal linkage, adjust clevis
danger zone. 18-3 to take up any slack in the valve push rod.

If the articulation lock is not fitted you could be Note: If there are two holes in the brake pedal lever,
crushed between the two parts of the chassis. connect the valve push rod to the upper hole.
GEN-3-1_1
3 After refitting the valve, start the engine and wait for a
Removal few minutes until the accumulators are charged.
Bleed the service brakes as described in Bleeding
1 Park the machine on firm, level ground. Apply the the System ( G-12).
parking brake and stop the engine. Securely chock all
four wheels. Repeatedly apply and release the
service brakes and parking brake until all the
pressure in the accumulators is exhausted.

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

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

2 Disconnect and blank all hydraulic hoses having first

Fig 18.
identified them to ensure correct replacement.

3 Identify then unplug the electrical connections from

the three pressure switches.

4 Remove the clip 18-1 from the foot brake push rod
assembly.

G - 24 9803/4160-11 G - 24
 Section G - Brakes
Brake Valves
Foot Valve

Dismantling and Assembly Remove only sufficient components to gain access to the
seals. DO NOT dismantle further.
The valve may only be dismantled to renew seals. If any
other part fails the complete valve must be renewed. Two repair kits are available: one consists of all the seals
and the other is a repair kit for the brake linkages and
includes the necessary rubber gaiters.

Fig 19.
5 Accumulator inlet adaptors (2 off)
Key
6 Low pressure warning switch
1 Brake valve
7 Pilot valve adjuster
2 Foot brake push rod assembly
8 90° Adaptor (return to tank)
3 Brake light switch
9 Tee adaptors (brake supply)
4 Transmission dump switch
10 Adaptor (Pressure from pump)

G - 25 9803/4160-11 G - 25
 Section G - Brakes
Brake Valves
Foot Valve

11 Adaptor (Return to tank via loader valve)

12 Straight adaptors (2 off)
13 Seal washer (4 off)
14 Seal washer (M18)
15 Seal washer (5 off)
16 Adaptor (Return to tank)

G - 26 9803/4160-11 G - 26
 Section G - Brakes

Parking Brake
Type 1

Dismantling and Assembly For assembly the sequence should be reversed.

The numerical sequence shown in Fig 20. ( G-27) is When Assembling

intended as a guide to dismantling.
Lightly grease all pivots and working surfaces, taking care
Note: Washer 20-4 is now integral with nut 20-2. to avoid grease contacting the brake pads.

Fig 20.

G - 27 9803/4160-11 G - 27
 Section G - Brakes
Parking Brake
Type 2

Type 2

Dismantling 6 Install lever 21-10 making sure the small diameter of

the spring 21-14 is piloted on the outside of the four
1 Disconnect actuator cable and remove brake. pins in the lever.

2 Remove friction pads 21-4 and 21-5. 7 Set the lever 21-10 in the 4 o’clock position.

Note: Before dismantling, mark the relative position of the 8 Install washer 21-11 and anti rotation clip 21-12, with
lever 21-10 to the shaft. The lever MUST be refitted in the its tab inserted into the lower hole in the lever.
same position.
9 Insert screw 21-13 into rotor assembly shaft 21-6 and
3 Unbend anti-rotation clip 21-12, remove screw 21-13, tighten to 12.4-15.8Nm (110-140 in.lbs.), while
clip 21-12, washer 21-11, lever 21-10 and spring 21- guiding lever 21-10 over rotor assembly spine.
14.
10 Bend up tab on the ant-rotation clip 21-12.
4 Push out rotor assembly 21-6 from casting 21-9.
11 Install the friction pads 21-4 and 21-5.
5 Remove 3 ball bearings 21-8.
12 Stroke lever 21-10 in the correct direction. The lever
6 Only if shaft seal 21-15 requires replacement. Press must rotate through 60 degrees of rotation. Return
out plastic shaft seal from casting using steel spacer lever to 4 o’clock position and make sure the lever
block 27.38mm [1.078in} diameter by 63.5mm [2.5in] side friction pad 21-5, is fully returned.
long and an arbor press.

7 Remove any plastic left in casting.

Note: Before assembly insure all parts are clean and

serviceable

Assembly
1 Insert seal 21-15 into casting with extended smooth
surface first. Using an arbor press with protective
spacer block, gently press seal until it snaps into
groove.

2 Grease ball pockets in casting 21-9, shaft and ball

pockets of the rotor assembly 21-6.

3 Insert 3 ball bearings 21-8 and ball spacer 21-7 into

the pockets in the casting 21-9.

4 From the inside of the casting 21-9, slide the shaft of

the rotor assembly 21-6 through the shaft seal 21-15
and seat ball pockets against the ball bearings 21-8.

5 Place the spring 21-14 over the large diameter pilot

on the outside of the casting 21-9.

G - 28 9803/4160-11 G - 28
 Section G - Brakes
Parking Brake
Type 2

Fig 21.

G - 29 9803/4160-11 G - 29
 Section G - Brakes
Parking Brake
Type 2

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G - 30 9803/4160-11 G - 30
Section H

Hydraulic Steering
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-11



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section H - Hydraulic Steering

Page left intentionally blank

H-0 9803/4160-11 H-0

 Section H - Hydraulic Steering

Contents Page No.

Technical Data
General data ........................................................................................... H - 1
Pump ................................................................................................. H - 1

Circuit Descriptions
Steering Operations ................................................................................ H - 2
General Description ........................................................................... H - 2
Steering Valve - Operation ................................................................ H - 2

Hydraulic Steering Unit

Dismantling and Assembly ..................................................................... H- 6
Dismantling ........................................................................................ H- 7
Inspecting .......................................................................................... H- 7
Assembling ........................................................................................ H- 7

Emergency Steering Pump

Dismantling and Assembly ................................................................... H - 11
When Dismantling ........................................................................... H - 12
When Assembling ........................................................................... H - 12

H-i H-i
 Section H - Hydraulic Steering

Contents Page No.

H - ii H - ii
 Section H - Hydraulic Steering

Technical Data
General data

Pump
Supply from hydraulic system. Refer to
Pumps ( E-134)

Steering Valve
Type Eaton Steering Control Unit ABV.

Relief Valve Operating Pressure bar kgf/cm2 lbf/in2

Shock valve 176 180 2550

Ram Dimensions mm in
Bore 80 3.1
Rod Dia. 50 2.0
Stroke 312 12.3

H-1 9803/4160-11 H-1

 Section H - Hydraulic Steering
Circuit Descriptions
Steering Operations

Steering Valve - Operation

General Description

H-2 9803/4160-11 H-2

 Section H - Hydraulic Steering
Circuit Descriptions
Steering Operations

H-3 9803/4160-11 H-3

 Section H - Hydraulic Steering
Circuit Descriptions
Steering Operations

H-4 9803/4160-11 H-4

 Section H - Hydraulic Steering
Circuit Descriptions
Steering Operations

H-5 9803/4160-11 H-5

 Section H - Hydraulic Steering
Hydraulic Steering Unit
Dismantling and Assembly

Hydraulic Steering Unit

Dismantling and Assembly

Fig 3.

H-6 9803/4160-11 H-6

 Section H - Hydraulic Steering
Hydraulic Steering Unit
Dismantling and Assembly

Dismantling
Use the numerical sequence on Fig 3. ( H-6) as a
guide to dismantling.

Before removing items 3-11 to 3-14, rotate the spool and

sleeve assembly within the housing until the pin 3-21 is
horizontal. Push the spool and sleeve assembly from the
housing just far enough to free the gland bushing 3-11.

Inspecting
Examine all contact surfaces and replace any parts that
have scratches, wear or other damage that could cause
leakage. Do not use abrasive or try to file or grind the
surfaces. Clean all metal parts with a solvent and blow dry
with air.

Assembling
1 Assemble the check valve

Lower check ball retainer 4-20 into the housing. Make Fig 4.
sure the retainer is straight in the valve hole and not
on its edge. Fit check ball 4-19 into housing. Lubricate 2 Assemble the spool and sleeve
and fit O rings (4-A 11.1 mm (5/8 in.) 4-B 15.9 mm (7/
16 in.)) to check seat 4-18. Install check valve seat 4- Assemble the spool 5-23 and sleeve 5-24 so that on
18 into the housing open end first; push the seat fully completion the spring slots 5-A line up at the same
into the housing taking care not to twist and damage end. Rotate the spool when sliding the parts together
the O-rings. Fit the set screw 4-17 and tighten to 11 and test for free rotation.
Nm (8.1 lbf ft2).

Note: When fitted the top of the set screw should be

slightly below the housing top surface.

Fig 5.

H-7 9803/4160-11 H-7

 Section H - Hydraulic Steering
Hydraulic Steering Unit
Dismantling and Assembly
3 Fit the spring assembly

Make sure the spring slots are lined up and insert the
spring installation tool (Eaton part number 60057)
through the slots. Assemble a set of low torque
springs 6-22, extend edge downward, with a pair of
spring spacers 6-B between two sets of centering
springs 6-C. Insert one end of the spring set into the
installation tool. Compress protruding springs and
push set into the slot at the same time withdraw the
installation tool. Centre the spring set in the spool and
sleeve assembly so that they push down evenly and
are flush with the upper surface of the assembly. Fit
pin 6-21 to the assembly making sure it is flush both
sides of the sleeve 6-24.
Fig 7.

5 Fit the drive end seals

a Place the housing 3-25 upright on a clean lint free

cloth. Lubricate all seals before assembly. Fit
seals 8-16 and the bearing race components 8-14
into the housing.

Fig 6.

4 Installing the spool and sleeve assembly

Position the spool and sleeve assembly so that the

splined end of the spool enters the valve housing as
shown. Push the assembly gently into place with a
slight rotating action until the parts are flush at the
insertion end face 7A. Check for free rotation of the
spool and sleeve assembly within the housing by
applying finger tip force to the spool splined end.
Fig 8.
Note: Do not move the spool and sleeve assembly beyond
the flush position because the pin 6-21 may drop into the b Assemble the Teflon seal components 9-13 (seal
housing discharge groove. 9-A, 'O' ring 9-B and back up ring 9-C) above the
bearing race 9-14.

H-8 9803/4160-11 H-8

 Section H - Hydraulic Steering
Hydraulic Steering Unit
Dismantling and Assembly

Fig 10.

6 Fitting the meter end seal and drive

Fig 9. Insert seal 11-9 into housing 11-25. Fit spacer plate
11-7 together with its seal 11-8 and align with housing
c Fit the dust seal 10-12, flat smooth side down, into bolt holes. Rotate the sleeve and spool assembly 11-
the gland bushing 10-11. Assemble the gland seal 15 until it is seen that the pin 11-21 is parallel with face
bushing over the splined end of the spool 10-15 11-A. Fit the drive 11-6 making sure it is fully engaged
and tap the bushing into place with a soft faced with the pin. Mark the drive head as shown at 11-B.
hammer, making sure the bushing is flat against
the bearing race. Fit the retaining ring 10-10
pressing it into position around the spool sleeve
10-24 with a screwdriver blade.

Fig 11.

H-9 9803/4160-11 H-9

 Section H - Hydraulic Steering
Hydraulic Steering Unit
Dismantling and Assembly
7 Time and fit the meter

Fit seal 12-4 into the groove on the meter 12-3.

Position the meter so that the seal is away from the
housing 12-25 and align the meter valleys as shown
at 12-C. Reference lines 12-A, 12-B and 12-C should
be parallel. Fit the meter over the drive head 12-6 and
align the bolt holes without disengaging from the
drive.

Fig 13.

Fig 12.

8 Fit and secure the end cap

Fit any drive spacers 13-5 that are required. Locate

the end cap 13-2 over the meter and align the bolt
holes. Fit seven cap screws 13-1 and pre tighten to 17
Nm (12.5 lbf ft). Finally, viewed from face 13-A torque
tighten the screws to 31 Nm (22.9 lbf ft) in the
sequence shown.

H - 10 9803/4160-11 H - 10
 Section H - Hydraulic Steering
Emergency Steering Pump
Dismantling and Assembly

Emergency Steering Pump

Dismantling and Assembly

Fig 14.

H - 11 9803/4160-11 H - 11
 Section H - Hydraulic Steering
Emergency Steering Pump
Dismantling and Assembly
Note: From the following serial numbers, 532847 (426)
and 534469 (436), the Emergency Steering System is
controlled by the Electronic Monitoring System. Details to
be found in Section F - Transmission - Electronic
Monitoring System.

When Dismantling
Mark position of cylinder barrel 14-14 and end covers 14-
10 and 14-27 to ensure correct replacement.

When Assembling
Renew bearings 14-23 and 14-26 if worn.

Renew shaft 14-20 if bearing surfaces are scored or worn

or if splines are worn or damaged.

Edges of bearing 14-18 must have a radius of 0.1 to 0.3

mm (0.004 to 0.012 in) to ensure correct lubrication. When
assembled to shaft, sleeve 14-17 and bearing 14-18
should turn easily by hand.

Cylinder barrel 14-14 should be renewed if cracked or if

piston bores are worn. Inner edge of piston bores should
be sharp and free from burrs.

Check for wear of ears on item 14-12 and on mating

surface of end cover 14-10.

After torque tightening bolts 14-9, check end float of shaft

14-20 which should be 0.1 to 0.5 mm (0.004 to 0.020 in).
Excessive end float could be due to worn shaft, worn thrust
washers 14-16 and 14-21, or wear on the end faces of
covers 14-10 and 14-27.

Base of pistons 14-7 should be smooth and polished.

Renew if worn or if clearance in bore exceeds 0.01 to
0.018 mm (0.0004 to 0.0007 in).

Table 1. Torque Settings

Item Nm kgf m lbf ft
5 70-80 7.1-8.1 52-59
9 50 5.1 37

H - 12 9803/4160-11 H - 12
Section K

Engine
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Hydraulic Steering
Section K - Engine

Publication No.
9803/4160-14



Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377
 Section K - Engine

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K-0 9803/4160-14 K-0

 Section K - Engine

Contents Page No.

Technical Data
426 and 436 ........................................................................................... K - 1
446 ......................................................................................................... K - 2
426B and 436B ....................................................................................... K - 3
426 from Serial No. 532500 .................................................................... K - 4
436 from Serial No. 534200 .................................................................... K - 5
426e from Serial No. 1295000 ................................................................ K - 6
436e from Serial No. 1410000 ................................................................ K - 7

K-i K-i
 Section K - Engine

Contents Page No.

K - ii K - ii
 Section K - Engine

Technical Data
426 and 436

426 436
Type Perkins 1006-6T7 Perkins 1006-6T4
4 Stroke, direct injection 4 Stroke, direct injection
Number of Cylinders 6 in-line vertical 6 in-line vertical
Capacity 6.0 litres (365 in3) 6.0 litres (365 in3)
Bore (nominal) 100mm (3.937 in) 100mm (3.937 in)
Stroke 127mm (5.000 in) 127mm (5.000 in)
Compression Ratio 16:1 16:1
Power Output
@ 1000mm barometric, 25°C 93kW ±5% @ 2200 rev/min 122kW ±5% @ 2200 rev/min
Max Nett Torque 404.9Nm @ 2200 rev/min 629.5Nm @ 2200 rev/min
Idling Speed 780 - 820 rev/min 780 - 820 rev/min
Maximum Governed Speed 2200 rev/min 2200 rev/min
Maximum No-load Speed 2370 - 2410 rev/min 2240 - 2280 rev/min
Fuel System
Injection Pump Type Lucas DPA rotary Lucas DPA rotary
Injector Pump Setting Code KK75L 1100/1/2420 RK90L1100/3/2310
Injector Timing 18° BTDC 17° BTDC
Injector Setting Pressure 250 atm 250 atm
Lift Pump Type Mechanical Diaphragm 2641A070 Mechanical Diaphragm 2641A070
Induction System
Air Cleaner Type 2 stage, dry element 2 stage, dry element
Maximum Air Cleaner Restriction 635mm (25 in H2O) 635mm (25 in H2O)
Lubrication System
Oil Pressure 280kNm2 280kNm 2
Oil Cooler Integral Plate Cooler Integral Plate Cooler
Max. Oil Temperature 125°C (257°F) 125°C (257°F)
Cooling system
Coolant Pressure 0.7 bar (10 lbf/in2) 0.7 bar (10 lbf/in2)
Coolant Temperature (Normal) 80-85 °C (176-185 °F) 80-85 °C (176-185 °F)
Coolant Temperature (Max) 103 °C (217.4 °F) 103 °C (217.4 °F)
Temperature warning light operates at: 98°C (208°F) 98°C (208°F)

For further engine details see Engine Manual Publication No. 9806/0100

K-1 9803/4160-14 K-1

 Section K - Engine
Technical Data
446

446

Type Cummins C Series, 6 cylinder turbo charged diesel, water cooled

Model 6CT 8.3 - 170
Power 170 hp @ 2200 rpm governed speed
Bore 114 mm (4.49 in)
Stroke 135 mm (5.32 in)
Displacement 8.3 litres (504.5 in3)
Compression Ratio 17.3:1
Firing Order 1, 5, 3, 6, 2, 4
Valve Clearance (cold)
- Inlet 0.3 mm
- Exhaust 0.61 mm
Dry Weight (approximately) 590 kg
Fuel System BOSCH MW/RSV
Injection Timing (static) 16° BTDC
Injector Opening Pressure 207-210 bar
Induction System
Air Cleaner Type 2 stage, dry element

For further details, see engine service manual.

Note: New engines DO NOT require a running-in period.

The engine/machine should be used in a normal work
cycle immediately; glazing of the 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).

K-2 9803/4160-14 K-2

 Section K - Engine
Technical Data
426B and 436B

426B and 436B

Type (New 1000 Series) 1006-6T 1006-TW

426B 436B
YK50598 build YK50599 build
Bore (nominal) 100mm (3.937 in) 100mm (3.937 in)
Stroke 127mm (5.000 in) 127mm (5.000 in)
Cylinder Capacity 3
6 litres (365 in ) 6 litres (365 in3)
Power Output at 2200 rev/min 107.4 kW (144 HP) 119.3 kW (160 HP)
Compression Ratio 17.25:1 17.25:1
Idling Speed 800±20 rev/min 850±10 rev/min
Rated Speed (Full Load) 2200 rev/min 2200 rev/min
Max. No-Load Speed 2350 rev/min 2350 rev/min
Peak Torque at 1400 rev/min 588 Nm (433.6 lbf ft) 439.9 Nm (324.4 lbf ft)
Fuel System
Injection Pump Type C.A.V. Rotary Distributor C.A.V. Rotary Distributor
Governing Mechanical Mechanical
ISOSetting Code 2644K206 BH/1/2350 2644K504 DH/1/2350
Injector Setting Pressure 250 atm 250 atm
Induction System
Air Cleaner Type 2 stage, dry element
Maximum Air Cleaner Restriction 635 mm (25 in) H2O
Lubrication System
Oil Pump Type Eccentric rotor
Oil Pressure at maximum speed 2.8 bar (40 lbf/in2) (min)
Oil Temperature 125°C (52°F)(Continuous), 135°C
(58°F) (Intermittent)
Oil Capacity 5000 cm3 (305 in3)(min), 6500 cm3
(396 in3) (max)
Cooling System
Coolant Pressure 0.8 bar (11.6 lbf/in2)
Coolant Temperature (Normal) 80-90 °C (176-194 °F)
Capacity 15.5 litres (3.5 UK galls)

For further engine details see Engine Manual Publication

No. 9806/2140

K-3 9803/4160-14 K-3

 Section K - Engine
Technical Data
426 from Serial No. 532500

426 from Serial No. 532500

Type New BTAA 5.9 - C / SO 18487 Tier 2

426 from Serial No. 532500
Bore (nominal) 102 mm (4.02 in)
Stroke 120 mm (4.72 in)
Cylinder Capacity 5.9 litre (360 in3)
Gross Power Output at 2200 rev/min 150 hp (112 Kw)
Compression Ratio 18: 1
Idling Speed 850 ± 20 rev/min
Rated Speed (Full Load) 2200 rev/min
Max. No-Load Speed 2370 rev/min
Max. Net Torque at 1500 rev/min 630 Nm (465 lbf ft)
Fuel System
Injection Pump Type Bosch VE
Governing Mechanical
ISOSetting Code Not Used
Injection Timing Plunger 0.65 mm (0.026 in) @ TDC
Induction System
Air Cleaner Type 2 stage, dry element
Maximum Air Cleaner Restriction 635 mm (25 in) H 2O
Restriction Indicator Vacuum switch on air cleaner inlet
Lubrication System
Oil Pump Type Concentric gear
Oil Pressure at maximum rated speed 50 psi (3.45 bar) @ 2200 rev/min
Oil Pressure at idle speed 10 psi (0.7 bar) @ 850 ± 20 rev/min
Oil Capacity With Filter 14 litre (3.1 UK gal)
Cooling System
Coolant Pressure Cap Setting 15 psi (1.03 bar) max
Coolant Temperature (Normal) 82 ºC - 110 ºC (179 - 203 ºF)
Thermostat Opens at 84 ºC (183 ºF)
Thermostat Fully Open at 93 ºC (199 ºF)
Capacity 35 litre (7.7 UK gal)

K-4 9803/4160-14 K-4

 Section K - Engine
Technical Data
436 from Serial No. 534200

436 from Serial No. 534200

Type New BTAA 5.9 - C / SO 18521 Tier 2

436 from Serial No. 534200
Bore (nominal) 102 mm (4.02 in)
Stroke 120 mm (4.72 in)
Cylinder Capacity 5.9 litre (360 in3)
Gross Power Output at 2200 rev/min 173 hp (129 Kw)
Compression Ratio 18: 1
Idling Speed (Normal) 850 rev/min
Idling Speed (Minimum) 700 rev/min
Idling Speed (Maximum) 1100 rev/min
Rated Speed (Full Load) 2230 rev/min
Max. No-Load Speed 2370 rev/min
Max. Net Torque at 1500 rev/min 740 Nm (546 lbf ft)
Fuel System
Injection Pump Type Bosch VE
Governing Mechanical
ISOSetting Code Not Used
Injection Timing Plunger 0.65 mm (0.026 in) @ TDC
Induction System
Air Cleaner Type 2 stage, dry element
Maximum Air Cleaner Restriction 635 mm (25 in) H 2O
Restriction Indicator Vacuum switch on air cleaner inlet
Lubrication System
Oil Pump Type Concentric gear
Oil Pressure at maximum rated speed 50 psi (3.45 bar) @ 2200 rev/min
Oil Pressure at idle speed 10 psi (0.7 bar) @ 850 ± 20 rev/min
Oil Capacity With Filter 14 litre (3.1 UK gal)
Cooling System
Coolant Pressure Cap Setting 15 psi (1.03 bar) max
Coolant Temperature (Normal) 82 ºC - 110 ºC (179 - 203 ºF)
Thermostat Opens at 84 ºC (183 ºF)
Thermostat Fully Open at 93 ºC (199 ºF)
Capacity 35 litre (7.7 UK gal)

K-5 9803/4160-14 K-5

 Section K - Engine
Technical Data
426e from Serial No. 1295000

426e from Serial No. 1295000

Type QSB6.7/SO 75928 Tier 3 ???????????

Bore 107mm (4.12in)
Stroke 124mm (4.88in)
Cylinder Capacity 6.7 litre
Gross Power Output at 2200 rev/min 160 hp (119 Kw)
Compression Ratio 17.2: 1 ???
Idling Speed 850 ± 20 rev/min
Rated Speed (Full Load) 2200 rev/min
Max. No-Load Speed 2430 rev/min
Max. Net Torque at 1500 rev/min ??? Nm
Fuel System
Injection Pump Type Bosch CP3.3 common rail
Governing Electronic
ISOSetting Code N/A
Injection Timing Electronic
Induction System
Air Cleaner Type 2 stage, dry element
Maximum Air Cleaner Restriction 635 mm (25 in) H 2O
Restriction Indicator Vacuum switch on air cleaner inlet
Lubrication System
Oil Pump Type Concentric gear
Oil Pressure at maximum rated speed 55.1 psi @ 2200 rev/min
Oil Pressure at idle speed 10 psi (0.7 bar) @ 850 ± 20 rev/min
Oil Capacity With Filter 17.5 litre
Cooling System
Coolant Pressure Cap Setting 15 psi (1.03 bar) max
Coolant Temperature (Normal) 82 ºC - 110 ºC (179 - 203 ºF)
Thermostat Opens at 88 ºC
Thermostat Fully Open at 96 ºC
Capacity 35 litre (7.7 UK gal)

K-6 9803/4160-14 K-6

 Section K - Engine
Technical Data
436e from Serial No. 1410000

436e from Serial No. 1410000

Type QSB6.7/SO 75928 Tier 3 ???????????

Bore 107mm (4.12in)
Stroke 124mm (4.88in)
Cylinder Capacity 6.7 litre
Gross Power Output at 2200 rev/min 173 hp (129 Kw)
Compression Ratio 17.2: 1 ???
Idling Speed 850 ± 20 rev/min
Rated Speed (Full Load) 2200 rev/min
Max. No-Load Speed 2430 rev/min
Max. Net Torque at 1500 rev/min ??? Nm
Fuel System
Injection Pump Type Bosch CP3.3 common rail
Governing Electronic
ISOSetting Code N/A
Injection Timing Electronic
Induction System
Air Cleaner Type 2 stage, dry element
Maximum Air Cleaner Restriction 635 mm (25 in) H 2O
Restriction Indicator Vacuum switch on air cleaner inlet
Lubrication System
Oil Pump Type Concentric gear
Oil Pressure at maximum rated speed 55.1 psi @ 2200 rev/min
Oil Pressure at idle speed 10 psi (0.7 bar) @ 850 ± 20 rev/min
Oil Capacity With Filter 17.5 litre
Cooling System
Coolant Pressure Cap Setting 15 psi (1.03 bar) max
Coolant Temperature (Normal) 82 ºC - 110 ºC (179 - 203 ºF)
Thermostat Opens at 88 ºC
Thermostat Fully Open at 96 ºC
Capacity 35 litre (7.7 UK gal)

K-7 9803/4160-14 K-7

 Section K - Engine
Technical Data
436e from Serial No. 1410000

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K-8 9803/4160-14 K-8