!!!!!!!!!!!!!!jcb_3cx_4cx_wsm2_sec_wat

       

     

     

     

 

    



          

                                                                                                                                        

  

                                   

                  

 

   



                                                                                                                            



                       



   

           

                                             



 

 

 

 





   



   



   



 



 



   



                    



 

          

 

 

 

 





                                                                                                                  

    























 

                                           

                    

         

    



















                      





  

 

 

 





    

        

                       

             



                       

                       





 

 

 



  

                              

                       





                           





 

General Information

 

 





Torque Settings                                       UNF Grade 'S' Bolts   



  

           

           

           

            

   

 

           

           

   

 

Metric Grade 8.8 Bolts             

         

            

          

         

         

Rivet Nut Bolts/Screws  

      



          

      

      

      

      

Note:                     



  





 

 





                                                                   

 

                                                                                                                                 

 

                                                                                      

                                                             

                                                                                                                                                                                                                                        

 

 

 

 





      



                                                          



                                                                                                                                                                   

                                                                                                          

                                 

  

                 

   

                                                

            

       

 

                      

    

                                                                         

          

 

 

 

 





      





            

            

                      

    

  

     

     

                             

                 



 

 

 

 





      

  

                 





                   





                                           

  





     



                                

                           

              

    







 

 

 

 





      

  

                                



                        

                    



               

                

        







 

 

 

 





                                   

                              





                                                                                    

















   





       





 

 

 

 





      

   



  





  





  











     





  









 

 





 

         



    





 

 

 

 





      

    



     

                                 





            

                                                                       

       

                                               



                      



                                                                                                                                                 



 

 

 

 





      

          

   

      



        

     

           

                     







  

         

                                                    

      

               



       

     

   

            

                   

                                                                 





 

 

 

 





      



                           

                           









       

                                                                       

   

              

 







   

                           

                         



 

 

 

 





      



                     



                  



        

                   

   







 

 

 

 

  

  

       



   

        







    

                 







  

     

  

        

 

 

      





 

 

 

 

  

  

      

 



       



      



    

 





    

   

                           





      











    

  





     

 

 

 

 

  

  

      

                  



                      





       



     



 





                        

       



 

 

 

 

  

  

      

                                         

   

       





           

 

             



 

 

 

 





     

                 



            



         



                        



 

     



 

              



          



   

        

 

  

  

          

 

 

             



   

  



 

   

  

 

   

   

  



 

  

    



  

      



 

          





    



 

Care & Safety

 

 





Contents



Page No.

 



 



 



 



 

Care & Safety

  

  

Safety Notices                         

 DANGER                           

 WARNING                     

 CAUTION                            



 

Care & Safety

 

 





                                                                                                   Remember BE CAREFUL BE ALERT BE SAFE 

General Safety

 WARNING Decals                                     

 WARNING Lifting Equipment                                               



 WARNING Care and Alertness                        

 WARNING Raised Attachments                     



 WARNING Clothing                                                              



  





Care & Safety

 

 





Operating Safety  WARNING

 WARNING Machine Condition                                   

 WARNING Controls                                



ROPS/FOPS Structure                                                                           

 WARNING



 WARNING Machine Limits                                   

Exhaust Gases                                                    



 WARNING Engine/Steering Failure                         

 WARNING Communications                                                 

 WARNING Engine                          

 WARNING Entering/Leaving                                              

 WARNING Ramps and Trailers                                   

 DANGER Sparks                                



 

Care & Safety

  

  

Operating Safety (cont'd)  WARNING                                                           

 WARNING Powershift Transmission

             

                                         



 

Care & Safety

 

 





Maintenance Safety  WARNING Repairs                               

 WARNING Battery                                   

 WARNING Modifications and Welding                                          

 WARNING Battery Gases                                                      

 WARNING Metal Splinters                                 

 WARNING Battery Terminals                         

 WARNING Electrical Circuits                   

          

 WARNING



 WARNING Communications                                                                             

 WARNING Petrol                             

Hydraulic Fluid                                                              

 DANGER Hydraulic Pressure                                         





 

Care & Safety

 

 





Maintenance Safety (cont'd)  WARNING Diesel Fuel                                            

 CAUTION Rams                                           



 WARNING Oil                                                                     

 WARNING Soft Ground               

 CAUTION Cleaning                 

 CAUTION 'O' rings, Seals and Gaskets                                   

 WARNING



 WARNING Tyres and Rims                                

Fires                                                                           

 WARNING Hot Coolant                                                   

 WARNING 

 WARNING Jacking                                                      

                         



 

Care & Safety

 

 





Maintenance Safety (cont'd)  WARNING

 WARNING

Hydraulic Hoses                                      

                         

 WARNING JCB Extradig Dipper Lubricant                                       



 WARNING Safety Strut                      





Fluoroelastomeric Materials                                     

 WARNING                                                               

 WARNING                                                                

 WARNING 

                                                                                                                    

 WARNING

        

                                    

                       

               

                                   



 

 

 

 





   



 



                                                                            



 

                       

          

  

       



          



    



    



         

 

              

  

             

  

                     

   

 

 

 

 







 

                       

   

            

 

               

     

               

     

          

     

          

     

       

     

  



 

  

          

        

      

     

        

  

        

  

    

  

         

     

       

     

 

 

 

 







 

             

      

      

  

  

                   

              

           

  

            



  

    

  

                                        

                             

 

 

 

 





   

   



 

 



 

    



 

  

 

         

  

             

     



             

    

                 

  

       

 





  

 

  





   

 

  





   

 

   

 

        





  





      



  





  





          











   

 

      

 

 

   

 

 





     

 

 

    



  





    



 





   

 

     

 

 

             

 





    

 

             

 



 

   



 

 

 

 

 

 





     

   



 

           





 



   

 

 



      

    

 





     



 





               

                                                                                                                                                                                                                                                                                                                    





             



 

 

 

 





                                            

 

                       

                                                                         

       





                                         

                                             



 

 

 

 

   

                                 

                       





 

 

 

 

        

                                        

            

              

                                                                

           



 

 

 

 

 

   

                     

          

     

                                        

     

 

 

 

 

     

                         

                                                    

                  

 

 

 

 

 

 

                     

                         

               

            

     

                   

             



 

 

 

 

 

     

 

                    

         

                

       

  

 

 

 

 

 

 

 

                                                     



                                                                                          



                            



 

 

 

 





           

                     

          

                            

 

 

 

 







 

 

 

 





             

       

             

                  

         

   

 









 

         

                  



         



  

  





 

 

 



  

               



 

 

 



  

                 



 

 

 

 





             

   

 









 









 

 

 



  

                





 

 

 



  

                





 

 

 

  

    

         

                                                                 

        



                 





 

 

 

 

  

  

           

       

   

                                                                







         





   

              















 

 

Routine Maintenance

 





Oiling Boom Lock - for Interval see Service Schedule

Parking Brake Cable - for Interval see Service Schedule                 



           



Control Levers - for Interval see Service Schedule           







 

Routine Maintenance

 

 





Loader Arm Safety Strut Fitting and Removing



              

                           X     



        Y Fitting

 WARNING The loader arm safety strut must be fitted before any work is done beneath raised loader arms. Make sure the shovel is empty, then fit the safety strut as instructed below.







1

        

2

  A    C    

3

   C              B

4





                    



Removing 1

              

2

  B    C       

3



         A

  



  

 

Routine Maintenance

 





 Slew Gearbox (Sideshift Machines) Draining Water and Checking Oil Level - for interval see Service Schedule Note:             1

Preparation                            

2

Draining Water   B          

3

Check Oil Level    A             





  



Routine Maintenance

  



  

Hydraulic Fluid Level

Hydraulic Tank Breather

Check Level      

Clean      

                                    

  C  D   E

        A                                           Note:       H   

  F      

   E      G Note:                       B                 Service Schedules

             B       

                                     

  



 



 





 

 

Routine Maintenance



  

Hydraulic Filter Renew Element for Interval see Service Schedule     A     B



  C   D   E        F   G

Note:                                                                     

    H          K

            E    D    C    



       B. Note:     J        





 

 

Routine Maintenance

 





Hydraulic Filter (from M/C Serial No 409448) Replacement

Renew Element Note:                                                                           A     

    H     J          G    F                       E           D    C    B    A      

Removal   A     B   C   

   

   D   E            F   E     G 



   



  





 

Routine Maintenance

 

 





Syncro Shuttle Transmission Check Level - for Interval see Service Schedule

Renew Filter - for Interval see Service Schedule

 

    E



                    

  F                    

   Change Oil & Clean Strainer - for Interval see Service Schedule      B            C         D Torque Settings  D

 

  

  





 

Routine Maintenance

 

 





Powershift Transmission Check Level - for Interval see Service Schedule

Renew Filter - for Interval see Service Schedule

 

    E



                    

  F          

  

         

Change Oil & Clean Strainer - for Interval see Service Schedule       B.     G            C         D Torque Settings  D

 

  

  





 

 

Routine Maintenance

 





Front Axle Oil Level

Check Hub Oil Level - for Interval see Service Schedule

Check Differential Oil Level - for Interval see Service Schedule

1

   OIL LEVEL      

1

   A.           

2

   C           

2

        

3

              C

     A        Change Differential Oil - for Interval see Service Schedule 1



   A    B          

Change Hub Oil - for Interval see Service Schedule 1

        OIL LEVEL             C   

Note:      B         2

     B       

3

         

          

  A            4

     A       



2

   C        

3

 OIL LEVEL    



4

            C           



5 

     C  

 

Routine Maintenance

 





 Rear Axle Oil Level (All Wheel Steer Machines) Check Differential Oil Level - for Interval see Service Schedule 1

2

   A           

Check Hub Oil Level - for Interval see Service Schedule 1

          

2

   C           



              C

              A.

Change Hub Oil - for Interval see Service Schedule

Change Differential Oil - for Interval see Service Schedule 1

   A    B        

2

     B

3

         

1

                   OIL LEVEL             C   

  A            4

     A

2

   C        

3

 OIL LEVEL    

4

        



   C.            5 

     C  

 

Routine Maintenance

 





Rear Axle Oil Level (2 Wheel Steer Machines)

Change Oil - for Interval see Service Schedule 1

Check Oil Level - for Interval see Service Schedule Note:                  1

        A           

2

        

                       OIL LEVEL                

     A



2

   C       B             



3

     B

4

   OIL LEVEL    

5

               A                

6

       C    A.





 

 

 

 

  

  

            

         

              



           



    

                                                                      



                                 



      

                             



               



  

                                                               





 

 

 

 

  

  

                  

                                



  



                                 

          

                                                                      



                  



                               



                                                                         



                          



                                             



                        







 







  

 

 

 

  

  

     

     

      

      

          

           

       

       



                  



                        



           



                 

                      



        



        

  

  



   



 

 

 

 

 

  

  

  

     

                

                       

      





              





        

                                



          



       

 

     

                  



                                                          

                                             



 

 





 

Routine Maintenance

 

 

  

  

Cooling System Check Level  for Interval see Service Schedule

Antifreeze                             

                                   

                   

1

     

2

                     A

Solution

Maintains circulation down to:    

Protects against damage down to:    











                                                                         

 WARNING The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the cap. Let the system cool before removing the cap. 

3

         

 Note:                                    



 

Routine Maintenance

    

    

Cooling System Drain and Refill - for Interval see Service Schedule

 WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before draining the system. 

1

     

2

      

3

    A         

4

   C        

5

                    

6

     D    

7

     

8

   C  D     

9

            A



 

Routine Maintenance

 

 

  

  

Fan Belt

Cab Heater Filter

Check Tension - for Interval see Service Schedule

Clean - for Interval see Service Schedule

 WARNING

Adjustment

The filter may be filled with dust. Wear goggles and a face mask when removing the filter.

1

     

2

  A B C  D   

3

        X     



 WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery. 

 CAUTION If any leverage is necessary, use a length of wood at the drive end bracket only; otherwise damage to the alternator may be caused.

1

     

2

           E.       

 

4

  A B C  D               

Note:                    

3

              

Note:                               4

             E







 

Routine Maintenance

    

    

Cab Heater Filter (From Serial No. 430001) Clean - for Interval see Service Schedule 1

                          

2

             E.

3

      F                       

Note:                 4

   E        

 





 

 

Routine Maintenance

  

    

AIr Filter Pre-Cleaner  Note:          Empty Pre-cleaner - for Interval see Service Schedule 1

  C     D

2

     E                

3

       

Note:                    Note:                    





 

Routine Maintenance

 

 

  

  

Air Filter Renew Outer Element - for Interval see Service Schedule

 CAUTION The outer element must be renewed immediately if the warning light on the instrument panel illuminates. 

Renew Inner Element - for Interval see Service Schedule                                    1

           H

 Note:                              

2

  A     B

1

  A     B

3

  E     F

2

      C

4

      C

3

   B.     D             

5

    G      

4

         

6

   F         

  A

            E

5

    C      

7

    B      D   

6

                   

8

            A

9

    H        





 

 

 

 

  

  

                                    

                                            

                                        

                                                                            







 



 

 

 

 

  

  

                                

                        

                                  



                                          



                              



                                                                                                      

                                            

                                               

 



 





 

 







 

 

 

 

  

  

                                        

        

       

                



                      



                     



                                



                              

 

                 

                   

 



                       

 

                     

           



                  



       





                          

  









 

Routine Maintenance

    

    

Battery  WARNING 

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. 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 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. When reconnecting, fit the positive (+) lead first. 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 minutes before connecting it up. 

First Aid - Electrolyte EYES           IF SWALLOWED                      SKIN       Cleaning the Battery                                                       Checking the Electrolyte Level

 WARNING Do not top the battery up with acid. The electrolyte could boil out and burn you. 

          

 

Routine Maintenance

 

 

  

  

Battery Jump Starting - Safety

Jump Starting - Procedure 1

              

2

Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

                                    

3

         

Batteries give off a flammable gas that can explode.

4

a                

 WARNING If you try to charge a frozen battery, or jump-start and run the engine, the battery could explode

Do not smoke when checking the battery electrolyte levels. When starting from another machine, make sure the two machines do not touch. This prevents any chance of sparks near the battery. Sparks could ignite the battery gas. If that happens the battery could explode. Even with the starter switch set to off some circuits will be energized when the external power supply is connected. Set all the machine switches to their OFF positions before connecting the external power supply. Do not connect a booster supply directly across the starter motor. Doing this could bypass the neutral safety switch and the engine can start with the transmission in gear. The machine could then run away and kill or injure bystanders.

b                    Note:                5

  

6

a            b            

Use only booster cables which are in good condition with securely attached connectors. Connect both ends of one booster cable before connecting the other one. 



 

 

 

 

  



  

                                 

  



                     



                        







     

                             



               



                              



  

 

                           





 

 

Routine Maintenance

  

    

Hydraulic Oil Cooler Clean  for Interval see Service Schedule 1

          

2

  A     

3

                     

4

   





 

 

Routine Maintenance

  

    

Bulb Replacement Headlight Bulb 1

    A        

2

     B      

Note:                     3

          

Front Sidelight Bulb 1

    A        

2

     B      

Note:                     3

   C   

4

    

5

         





 

 

Routine Maintenance

 

  

  

Bulb Replacement (cont'd) Note:                  Worklight Bulb 1

  H       J      

2

     J      L

3

  L

4

     M

5

Do not touch bulb with bare fingers    

6

      

Front Indicator Light Bulb 1

  A      

2

            

3

        

4

      





 

 

Routine Maintenance

 

  

  

Bulb Replacement (cont'd) Rear Brake/Sidelight & Indicator Bulb

 Note:

                   1

  A      

2

             

3

        

4

      

Fog Light Bulb (if fitted) 1

  B      

2

            

3

        

4

      





 

 

Routine Maintenance

 

  

  

Bulb Replacement (cont'd)  Note:           

Cab Interior Light Bulb 1

                

2

    G    

3

              

4

   F       

Number Plate Light Bulb 1

  B    

2

   C    

3

              

4

      





 

 

Routine Maintenance

 

  

  

Bulb Replacement (cont'd) Note:                 



Note:            Rotating Beacon Bulb

Switch Illumination Bulbs 1

    J   

2

                     

   E

3

   

4

Do not touch bulb with bare fingers.                  

4

      

5

      

1

  A      B

2

   C      D

3





 

 



 







 

                         

    

               

 

         

  

              



        

 

Attachments

  

   

  

Schematic Hydraulic Circuit Component Key 1

 

2

  

3

  

4

  

5

   

6

  

7

     

8

 





 

  

Attachments    

  

Circuit Description        2      3              4                             B   4      5          6   1          4                 P          7            C       P                   B            4       





 

Attachments

  

  

   

Flow Diverter Valve Removal and Replacement

 WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-2

Removal 1

2

                                            

3

                          

4

    

Replacement        

 WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immendiately. INT-3-1-10/1

                    E        P         B         T      Note:                                  





 

Attachments

  

  

   

Flow Diverter Valve Dismantling and Assembly

Torque Settings

             

 4

 

  

  

22







       When Assembling

                        

           





 

Attachments

  

   

  

Flow Testing & Pressure Testing





 

Attachments

  

 

   



Flow Testing & Pressure Testing  WARNING

4

Hydraulic Fluid

4.1                              

Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

4.2       E     F      

INT-3-1-10/1

 WARNING

Pressure Testing

5

                

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

Prepare the Machine 1

                             

2

              

3

Flow Testing 3.1                        A       X    Y    Z    

CAUTION:        Z              3.2          3.3          B     3.4                    C     D   

 

Attachments

  

     

                                                 A     B     A                   Inspecting the Top Wear Pads     B                               Adjusting the Bottom Wear Pads    

  

Inspecting the Top Wear Pads                         C     D                                    E                             

   A  B             

 

 











 

Attachments

  

 

     

Adjusting the Bottom Wear Pads



              

               

a     H     J

        C

b     H

  

c        

        F    

d          

       D               

     H        e               

 H       

                       A    G           

     G     a  c

Note:           Note:      J                 A  B                             F



  











 

 



 

 





  

 

 



  

       

 

                                                    

                                                               

 

                          



            



             



                            

           

                                           

                           

                       

          

 

 









 

 

 

Attachments

  

  

  5 4 3

1, 2 8 10

30

9

23 22



1

2

6

30A

19



26 7



25

27 28

24

 21 20



18 17 16

 

29A

15

29

14 13 12 11





 

  

Attachments

  

 

Auxiliary Valve                    Dismantling and Assembly                                                1

               1  7

2

3

                            19      13     24                                 1      X Y Z   X     10  18     A   

           8  23.

Relief Valves

        X   

   29  30                 

    24  28. 4

When Assembling

   29  30    

                  

When Dismantling

Torque Settings

   4        5

 1

   

   

   

8, 11, 13



  

  

        X Y  Z      6   7                  4       13   19                           1

   20 23    21 22.

2

       27    28    24     

3

   29A

4

   30A



 

Attachments

  

  

 

Pressure Testing Auxiliary Relief Valve (A.R.V.)                                 Note:           1

                A     

2

         

3

  3.1        3.2                          B      

4

  4.1        4.2                       B       4.3        C    D             4.4                       E        F    G            

3.3        C    D             3.4                          E  

      F    G            

 



  



 



 

    



   

    

 



                         

 

                                     

                                                                                                                         

    



   

   

 



                                                       

                                                                                                      

              

            

                                   

 

    



   

   

 



                                                           

                                                                                                      

              

               

                                              

                                            

 

 

  

 







 

       



     



      

 

    



    

  

                                                             

                                                                                       



                                         

                                                  

 

 

  

 









 

        

  

       

  

       

  

        

  

         

  

      

  

 

Body & Framework

 

 





Engine Side Panels

Engine Cover

Removal and Replacement

Removal and Replacement 1

 WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.  

1

   

 WARNING A hot exhaust will burn you. Make sure the exhaust stack is cool before removing it. 

     

 WARNING Do not remove the engine side panels while the engine is running. 

2

      

3

      A     

4

         

2

  F     D

3

  C    B

4

  E   G     H

5

    

       

   A







 

Body & Framework

  

  

Rivet Nuts Fitting Procedure                                                                                                                   1

                 

2

                             A

3

                      B

4

              1

5

  C                D                     E

Note:                  6

   

Specifications (all dimensions in mm)    

   

 











  

  

     

 





     

 





     

 





Note:                                         

 

 

Body & Framework



  

Slide Hammer Kit Procedures                                            A                               B  C                      

1

             

2

              A       D     

3

    B                   

4

    E             

5

     F      

6

      C                  

7

                C         

8

          





 

Body & Framework

    

    

Roll Over Protection & Falling Object Protection (ROPS/FOPS) Structure Checking

 WARNING The Machine is fitted with a roll over protection structure (ROPS) and a falling object protection structure (FOPS). You could be killed or seriously injured if you operate the machine with a faulty or missing ROPS/FOPS. Modified and incorrectly repaired ROPS/FOPS are dangerous. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been repaired and inspected by suitably qualified personnel. 

                                               A       B       C     





 

    



    

    

 

    

    

    

                                                

                                                                 

                                

                                                

                                                                                          

                           







 

    

  

    

 

 

 

                                        

                                                    

                                                                                 

                          

 





                                                    



             

                                  

                                              

                                          

                                        



                 



      

                                                



                                          

                                                



                                                               

                                       



 

 

  

  

    

 

                                                                                                                                                           

 

         

               



       

      

  



      

       

    



    

           

             

                                  

                         

          

      



                             



 

    

  

    

 

    

 

              

     

               

                              

   

    





 

 

  

  

 

 

  

      





                  

 

     



      

 

   



       

 

  



     

 

     



             

 

   



             

 

       



            

 

       



            

 

           



       

 

        

      

 

      

     

 

       

     

 

     

     

 

          



 

 

  

  

    

 

   

 

                                        

                                    

                                                            

                                          



                        



                        

 

 

                 

                         





                                             

                                

                                                                                                              



 

Body & Framework

    

4

                    

5

      

Removal Note:        1

  

2

    13     a

      1 2 

b

    3

c

   4

d

    7     5

e

  d     

   15    14                     

Thermostat

    b  f)

   6

3

  

 

Blower Motor

f

 

                   10             

 10

      

              

Compressor Clutch Relay

      11  12    12       X

12

                    

11



4

1

13 3

11

14

2

14

 12

7 5

11

14

14 15

6 10 8

9 



 

 

Body & Framework

  

    

 

Pressure Switches                        

Removal and Replacement

                                

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 and eyes.

 WARNING

 

                                 

Removal 1

Pressure Switch Testing 1

2

                                                                                        

        

Replacement Note:                       1

                 

2

                        

High Pressure Switch Testing 1

            1

2

 

                              

Low Pressure Switch Testing 1

                             2

2

                     



Note:               



 

Body & Framework

    

    

 

Condenser Coil

Adjusting the Compressor Drive Belt

                                                                                

 WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 

1

              

2

   

3

     

               

4

  A B  C

Condenser Coil Cleaning

5

          

                       

   X 6

  A   B  C

            

 WARNING

1

              

2

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system must be disconnected except by a qualified refrigeration engineer.

   



3

  



 WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery.





4

                   

5

   











 



 

    

  

 

      

                                                     

  

                                                      

                                                



                                                    



             

                                          





                 



      



                                          



                                                               

 

    

         

    







 

    

         

    

                                                                                                                                                                                                                                                        

                                                                                                                                                                                                                                                           

                                                                                                             



 

 

  

  

    

      

                                                                    

 

  

         

     

           

 

  



      

       

    



    

       

         

                                   

                   

40

122

41

92 94

93



95

42 

 

    

  

 

      

  

   





                  

 

     



      

 

   



       

 

  



     

 

     



             

 

   



             

 

       



            

 

       



            

 

           



     

 

      

     

 

     

     

 

          



 

 

  

  

 

      

   

  

 

                             

                                                                         

                   

                                                                                                        

                                   

                                                   

  

                                                                                              





 

    

  

    

      

   

  



            



            



       



      



        

                           

                                         









 

 





  



 

    

  

    

      

                                                                    

  

                                 

                                  



        

     

              



              



                                      

                 

                 



                        



    

              



              



                                     

  





 

 

  

  

    

      

                                                            



                                                                                 

                  



                         



   

















 

 

  

  

      

    

                                                       

                



                                



                    



       

 



 



 

    



Body & Framework 

    

 

Body & Framework

    

    



Glazing - General

Direct Glazing

                                   A  

                                

    B    Note:                                                 DO NOT                





1

        

2

                               

3

  

4

              

5

                 Service Tools  

                                      Service Tools  



                                                               Removing the Broken Glass and Old Sealant

Rubber Seal Glazing Installing New Glass                    1

      

2

                 

3

                   



Note:                                                    

 WARNING                                                                

 

 

Body & Framework

  

    



Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) 1

                       

2

a                                





b                    3

                        a

 

  A                       

               







 

        

        

                                b      B.                   



    C          

      D                            



                               E                             



 

 

Body & Framework

  

    



Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) c   F                        Service Tools   

      



               G





             

d

  H    



      



         

Note:                            Service Tools,           4







a             Service Tools   

b                5

                           J

6

          



a           b                 Preparing the Cab Frame Aperture 1

              

2

                             



Note:           

 

Body & Framework

    

    



Direct Glazing (cont'd) Preparing the New Glass



 CAUTION



The laminated front screen must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude. When placing or lifting the screen in a horizontal attitude it must be supported over its whole area, not just at the edges.  

1

           K



a     L        



b                Service Tools                 



Note:                                 IMPORTANT:                       2



                 N  Service Tools  



                     P        N                                                                3

4

                          





a                                       

Note 1            





 

 

Body & Framework

  

  



Direct Glazing (cont'd) Preparing the New Glass (cont'd) 5

 





 

       Sealing



  

and Retaining Compounds           



a                



b                                   c             d       S



e        Note 2:                   Service Tools                            6





                 T                 

Note 3:                                      7

                        





Installing the New Glass 1

             Preparing the New Glass

2

       a                         W b          



   X 

 

 

Body & Framework

  



    

Direct Glazing (cont'd) Installing the New Glass (cont'd) 3

     a            b

        

4

                

5

    

IMPORTANT:                              a                b                      Note 4:                                         c

6

        

           a         b            c                 



 

 

  

 

  

  

 



                        



           

    



                                                        

                                      



                             



        



           

                   



      



             



           



                       



        



                            



                      





         



                                         

                                       

                                                     



                         

             



             

                 



            

                                    



 

 

  

 

  

  

 















 

 

  

 

  

  

   

 

  

         

                                    

 



 

                



      



                      

             



            





        



      

                                        



                  

    



                     



                               

                            





                                                     

             



              



                                            

              

                         



                  

                                                    



 

 

  

 

  

  

 

 





 







  



 

  

 

  

  

      





       



            

                             



      



                     



   

                       

                                               

                         

                                               

   

                                 

                                                



 

Body & Framework

    

    

 Slew Cylinders (Sideshift Machines) Dismantling and Assembly       

 WARNING Slacken but DO NOT remove the cylinder retaining bolts when using hydraulic pressure to break the seal. Severe injury can be caused if the cylinder is released suddenly under pressure.  

  A           B         C          D                 E Note:                        E                F   G   



        B             Torque Settings Item A

Nm 

kgf m 

lbf ft 

E









 

    

  

    





 

 

  

 

  

  

                                                                                                                                                         

                                                                                                   

              

       

 

                

                                

 

                             

 

 

  

  

 

                       

                                                                             

2 - 4 MM









 

    

  

    





 

 

  

  

    



  



  

        

                                 

             



  



            



                 



                                                       

            

                                                                                                                                                                      



 

         

   

               

 

       



  

 

       

 

         

                   

 

                                           

                                                                                                                    



                                                                                                                   

 

 



 







 

 

                                                                                                                                                      



       

    

  

                   

                                          

           



      

        

   

        

        

  

 

 



 





 

            

              

                 

              

                

     

                                                   



 

                          

 

  

  

  

    

   

                     



       



                    



       





  



     



      

     

      

 



     



 

    

  



 



 



  

   





 



   

  

    

  

        



 

 





 

  

            

                                            

 



               

 





      

   



   



    

 

    

 



 

 



  

 



  

 







    

  

 

 



                   



           

 

 







     

 



    



 

 



 

 



  

 



  

 



 

 







  

 

                                                     

   

 





  



    



            



  

   

                   

 

  

 

        

 



 

 





  

 

                   

 

               

                                                           

 

                                                                                        

                 

                                  

           

4W



                             



 

 





  

 

                                                                                                                                                          

                                        

                                          

                                      

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



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 









 

 





  

 

                         

                                                   

                                                     

                                     

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    

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

 



 



 

 





  

 

                                                



   

                       

 

                                             

                                                           



   

 











P











 



 

  



 









4W 















 

Electrics

  

  

 

Use of Multimeter             



  

C

A B

 

1

                                                           

2

                            

3

                                                                                     



 

  



Electrics  

  

 

  

Electrics

 

 



Measuring DC Voltage          B            A                                                                

Measuring Resistance                                                             C                   F         G                REL                           B                           

Measuring Continuity                                                             C                   F         F                                        B         C                                                         



 

  

Electrics  

  

How to Test a Diode or a Diode Wire                                       D   HOLD      H                                                                                                               O.L          HOLD      H                       A,         C                                                                                                                                                                                                                                 



 

    

Electrics

    

  

Adjustment Note:               A  B                               C                  C      D                           

  



   





 

Electrics

    

    

Basic Machine Component List (to serial number 430000)                                                                             

                                                                                                                                                         



                                

    

                                                                                                                                                                                                                      

Fuses                          

 

Electrics

    

    

    

Circuit Options and Variations 2/4 Wheel Drive (all machines up to serial number 409434)

Transmission Dump Circuit (machines up to serial number 413772)

Component List                                

Component List                                               



34  



32

 



35  



36

 

37



31 

A1

C3 2





 

Electrics

    

    

    

Circuit Options and Variations Instrument Lights Test Button (machines up to serial number 404502)

Hydraulic Speed Control - 2 Relays (machines up to serial number 406613)

Component List                                       

Component List                            









21

23

25

85



20

22

89

24  

86



88





88   

 

 

87





A2

19 29

2

B1

B9 





2



 

    



    

    

                                                                                                                                                                                            

                                                                                                                                                              



         

                              

                  



 

    

     

    

                                                           

              

                                                                                                                                                                      



 

    



     

    

 

    

     

    

     



 

    



     

    

 

    



 

    

  

                                                                                                                                                                                



                                                                                                                                                           

 

 



  

    





 

                                                                                                                                             

        

               

                 



                            



                       

                         

     



             



            

                                                             



 

    



    



                                                            

                                                                        

      

              

 

 

 

     

     

     

                                                      



                           

               

         

          

      



        



                     



                   

     

         



                 



         



          



 



  

                         

 

 



  

    

  

  

 

                                             

    

                                                                           

   

 



                               



                                                                                       



               



                                                                                          



   



    



                                                  

                



                                                                



 





 

    



    

  

              



             





                             







                                               



               

 





 

    



    

  

                                                                            





                                                 

 

                                                 

                                



                              



                    









 

Electrics

    

    

 

Starting Circuit Test  

                    

 

                   

Test 3        C           

                                  



Note:                           Test 1                    



           Test 3a                 D                     



Test 2         A

F N R





     B                                                  







+ -

 







 







 

Electrics

    

    

 

Starting Circuit Test (cont'd) Test 5

Test 3b

           A                               

     D           E                                    



    E                             Test 4           B              

 

Test 5a                              H                

 

                







     

 

    

Electrics  

    





 

    

Electrics  

    

Removal and Replacement                                     

Dismantling Note:     34                    15        23      22    28       11   

Servicing and Renewal   14  14A        

Assembly   C        28              14A                           19             24               D        17     18    

   A                                                           B     14A                  14A     15                       36          

 

   32  34  



 

 

Electrics

 

  



  

Charging Circuit Test                            

Check 2 Note: the following checks should be made using an analogue (moving pointer) type meter.          

                                 

 

                                          

       1                     2                 Check 1           

         

           

Alternator Charging Test

                    



                                                                  

 

                                                          

                     Note:                  



 

 

Electrics

 

  



  

                          a

  

b

     

c

 

d

 

e

       

f

       

    a             



    b  c                                  d e  f             



Terminal 'W' Output (Tachometer) Test                                                     



 

 

Electrics

 

  



  

Service Precautions a

           

b

                                  

c

                            

d

                      

e

                                            

 



Removal and Replacement         A B  C                          B  C        D         A   



 



 

 

Electrics

 

  



  





 

 

Electrics

 

  



  

Dismantling and Assembly When Dismantling   2      1    E   F   3    G   H         4                                     5  6   7      8.    10   11         X Y  Z            12                      19      17                            17            20           When Assembling            1416  18           J                 9   5                    Torque Settings Item 3

Nm 

kgf m 

lbf ft 

5







6







7







12









 

 

Electrics

 

  



  

  

 











 













 

 

Electrics

 

  



  

Dismantling and Assembly - Magneti Marelli Type When Dismantling   1   2        A                          6           3   4   5 

When Assembling                                                    

      6      7      8                                 B                 9,  10   11            12      

Torque Settings Item 1

Nm 

Kgf m 

lbf in 

4







5 







5 







Item

Nm

Kgf m

lbf ft

9







 13



 

Electrics

    

    

 

Harness Location - Machines upto Serial Number 430000

4

3 6

1

2

5 

Note:      

ITEM

DESCRIPTION

     

                



 

Electrics

    

    

 

Harness Location - Machines from Serial Number 430001 3

4

2

6

7

5

1

Note:      

ITEM

DESCRIPTION

      

                   



 

    

     

    

                                                                                                  



                                                                                                                       

  

                            



         

 

                                                                                                                                                                                        



 

 



 

  

  

                                                                              

    

        

   

           

       

   

      

     

   

 

      

     

   

 

      

     

   

 

      

   

 





                                                      

                                                                       

                  

    

   

 

      

    

   

 

      

    

   

 

      

  

 









  

 









                         

                           

         









           





                                        

 

 



 

  

  

                                                                              





 



   

      

 

      

     

      

 

      

  

    









  

     







  

   









  

   









     

    

 

      

 

   









   

   









   

   









                           

                        

        

              

           

       

   

             

   

  









   

  









   

  









   

     









                                                      

                                                 

              

                                     



 

 



 

  

  

                    

                               

    

           

       

                                       

                                            

                  

                               

                    

           





   

   







 

   

 

 



 

  

  

                 



 

  

  



                

                               

                                                     

                                                         

               

      

        

 

 

      

               

          

   

      

       

     

 

      

     

     

 

      

   

   





  

 

 



 

  

  

                                                                              

                      

                  

      

      

          

     

  

      

       

    

 

      

       

      

 

      

      

     

 

      

      

    

 

      

                                                                                                

                                                                                   

                          

      

      

     

 

      

       

     

 

      

                   

                   

     

           





 

 



 

  

  

                                                  

     

                            

                         

  

          

      







     







    

   









    

   









    

   









    

   









   

    









   

    









   

    









  

  









  

   









     

         

  







           

           

     



   

 

 



 

  

  

                                                                     

                                                                                  

                                                                       

                       

      

                           

                       

        



                                         

                                 

          

      

  

 









  

 









        

                 

   







 

                                           



 

 



 

  

  

                                                                              

                                               

                                                     

              

       

         

  

      

                                                                    

                                                                

              

      

        

     

 

      

                 

             

  



             

              

   

      

                                                   

                                                 

               





              





       

 

    



    

    

                                                                                                                                 

                                                                                                                                                                                                                                                                                                



                                                  





 

                             

     

  









         



          





 

    



    

    

           



                                             

                                                                                                                                                                                                                                            



                                          



    

     







          

      

 



    

 

    

         





 

    



    

    

                                                 



                                                                                                                                                                                                                                           



       





             

        



               

     





       



 





 

    



    

    

           



                                                                                                                                                                                                                                                                                                                                                                                                          

                                                      





     





         

  

    

           

  

  

    

 

                   

    



    

    

           



                                                                                                                                                                                                                                                                                                                                                                                                     

                                                       





     





                           



         







       



 

  

  

    



    

    

           



                    

                                                                                           



              







         

     













   

 

 

    



    

    

           



                                                                

                                                                                                                                                                                                                                                                                                                                                  



                                                        



      



     

        





 

   



  

  

 







      

           

   

          

  

    

   

  

    



    

    

           



                                                              

                                                                                                                                                                                                                                                                                                                          



                                                       



  

      





      









               

     



    

     

   

      

   

      

 

    



    

    

           



                                                                  

                                                                                                                                                                                                                                                                                                                                              



                                                       



      

   



 





  



     

              

     





     

   



                 

          

  

     

    



    

    

           



                                                                               

                                                                                                                                                                                                                                                                                                                                                                              



                                                          





     





           

  

 

 

    

  

  

 

        

 



 





                  

 

 



   

    





 

    



    

    

           



 

             

                                                                                     

             





 

     

   

     





 

     

                                                      



 

 



 







 

        



       



                                                                                  





           

  

           

  

 

  

Controls  

Loader Control Knob                                

  

When Assembling         5    Note:  5           

                             Note:                    Dismantling and Assembly                      When Dismantling            1    2   3     4  5    6       





 

Controls

  

 

  

28

D







 

  

Controls

 

 



Tilt Type Steering Column When Assembling

 

                                      Dismantling and Assembly



  20         

             

Note:       

      

         D

 

                                                  

 

                   D              

When Dismantling                              



             14   22

          28                                

  20     

  8       9 

 

     14   

 12                 20          22    21            B            A        19           20            C                                 D The shaft must not touch the bottom of the splined socket.           16   

        11    13         22



 

  

Controls

  

 

D







 

  

Controls

  

 

 Fixed Type Steering Column When Assembling

 

                                     

 

            13   26   24        

Dismantling and Assembly              



Note:          24               D

      

 

                                                  

 

                   D               When Dismantling                              





          14           14A            14  15                                

     11 16  25



   15          14          Note:              14A

 

            9     19    18         24          26    25            B            A        23           24                                   C The shaft must not touch the bottom of the splined socket.

          16   

        11    16.         26



 

  



  

 

  

  





  



  



  

 

                                                                                                  

 

                             



      



           



                



                                  



                               



                



  

    



    

 

                                                                                         

                                                                                             





 

    

  

    

    



           

           

       

                  

                                        

                                            

    





 

    



    

 

          

                                                                                





       

            



              



                       



                     



                              



          



          

   





 

 



  

    

 

      

 



  





 

    



  

 

               

 

                             



                  



        



      



   



              

                                           

       

        

                             



              



          

                                                                                                             

                       

       



                         



       



           



          



 



 

    



    

 

                                                             



   

          



          



                   







          



      



                        









 

 



 







 

                    

   

                            

    

           

 

                           



       

  

  

 

  

          

 

    



    



       

 

           

 

 



      



      

  

            

  

         

  

 

 



 









      

  

             

     

    

  

     

  

                   

     

                      

        

    

  

       

  

  

  

          

     

          

     

                

        

                                  

              

                                   

              

       

 

       

 



 







 

   



  

          

  

        

  

       

  

       

  

       

  

          

  

      

  

                                                        

     

                          

                 

                    

           

                                        



                 

 

 



 







 

                                    



              

     

  

                            

     

                          

        

                       

        

                              

           

         

  

      

  

         

     

          

     

    

  

            

     

    

  

 

 



 





       

  

         

  

         

     

   



 

  

 

 





  

 

                                                                                                                                                     

                              

                              

                              

                              

     

   





    













 

















                                   



 

 





  

 

                                                                                                                                                 

                                 

                                 

                         

                         

     

   

















    















                                         

 

  



  

 

             







      



  

  

  

 



  

  

  



     

     

     

  

  

  

     

     

     

        

        

        

                 

                 

                 

                         

                         

                         







        

        

        

  

  

  

  

  

  













             

                                                                                                            

 

                                                       



                                                                                           



 

  



  

 

                         

                       

               

                   

               

                   

       

  

               

   

   

                          

       

                   

                           

                

       



                               

                           

  

   

   

 

  



  

 

                    

                       



          



                                           









  

  

  



     

     

     

     

     

     

     

     

     

     

     

     

  

  

  

     

     

     







                                         

3

1

2

5

2A

6

2B

4

3 

  

 

  

 

  

            

  

  

     

  

                                                          

                                                                                                                                                                                                    



              

                                                              

                              

                              

 

 





  



                                                                          4 61

4S

4B 4K

C2

 

V2 V1

C1

4L

      

52



                         

                                            

1A 3M

3   3L

3N

3P

3Q

T

P2 P1



         

                             



 

 





  



                                 

          

                       

1B 62

T

4

4G 4X 4R

4H

4A





 

ng

hi

et om xs Fi

 



 







ng

hi

et om

xs

Fi 

 

 



 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 



 







ng

hi

et om

xs

Fi 

 

 



 







ng

hi

et om

xs

Fi 

 

ng

hi

et om xs Fi

 



 







ng

hi

et om

xs

Fi 

 

 



 







ng

hi

et om

xs

Fi 

 

 



 

  



  

ng

hi

et om

xs

Fi 

 

 



 

  



  

ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

 

Hydraulics

 







ng

hi

et om

xs

Fi 

 

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

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ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

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ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

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et om xs Fi

ng

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ng

hi

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ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

 

Hydraulics

 

  



  

ng

hi

et om

xs

Fi 

 

 



 

  

 

  







                                                                                                                     

         

      

      

      

     

    

      

         

  

        

       

      

  

 

 

        





 

 



 

  

   

  





 

            

  

      

    

      

    

         

    

       

 

Fi

   

et om

xs        



ng

hi

     



 



 

 



 

  

   

  





        

      

 

 

      

 

 

  

 

  

  

 

 

     

       

     

      

    







     

 

 



 

  

  

   





    

  

       

  

                                      

 

 

 

Fi

 

 

 



ng



hi

    

et om

xs  



 

 



 

  

   

  



  

 

 

 

 

                                                                                                                       

                         

 

 

                                                                        

 

 

                                                                                                            





 

 



 

  

  

   





                                                        

         

               

                                                                   

A

B

C

G

D F

E

ng

hi

et om

xs

Fi 



 

 



 

  

 

  

  

  



  

      

  

     

  

          

  

          

  

   

  

    

  

 

  

    

  

        

  

      

  

 

      

                                                                    

              



        



              



               



          



                       



           

 



  

       

   

    

 

          

     

    

  

        

  

    

   

    

     

      

 



 

 



 

  

 

  

 



 

     

          



          

      

  

        

  

         

     

    

 

            

   

    

  

    

         

    

  

       

     

    

       

                                                

       

Fi

      

xs

   

         

    

         

et om



     

            

  

          

ng

hi

  

     



      

 

 



 

  

 

  

      

     

              

    

                 

      

  

      

        

  

  

    

          

   

       

    

  

        

                 

      

       

      

    

         

        

 

        

    

           

     

   

       

    

       

     

    

   

  

   

 



    





 



 



 

 



 

  

 

  

 



 

    

        



  

    

    

    

       

  

     

    

  

       

  

        

       

     

    

          

    

                             

     

              

 

                        

Fi

  

     

xs

       

    

et om

     

hi

       



                    

ng

 

          

                 

    

 

    







 

 



  

    



                                             



                                                              

 

     



                  





                                    



                    

                                     

                              



                  





                    



                                              

                                          

                 



                 

                                                                     



                                  



ng

                          

hi

et om

xs

Fi



 

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

ng

hi

et om xs Fi

 



  

    



  

  

 

       

                                                    

                                                              

        



                    

              

         

 

           



              



                            



           

                                  

               







 

 





 

 



  

    



ng

hi

et om

xs

Fi 

 

 



   



    

                                                                                                            



    

     

     

 

 



  

    



ng

hi

et om

xs

Fi 

 

 



   



    

                                                                                                                                                       



    

     

     

 

 



  

    



ng

hi

et om

xs

Fi 

 

 



   



    

                                                                                                                                                                          



    

     

     

 

 



   

    



          

 

             

           

                                  

  

   

   

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hi

et om

xs

Fi 



 

     

 

    

          

 

             

   

      

                                      





 

 



   

    



                                                   

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Fi 



 

    

 

    





 

 



   

    



                                                                                                              

   

    

    

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Fi 

 

 



   



    

                                                          

   

         





 

 



  

    



   

 





  

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

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



 

 



  

    



        

 

             

                     

      

                                 

           

  

       

                                                                    

                                             

   

    

    

                                                                                            



 

 



  

    





 

   



 

 

   

 

xs

Fi

  

et om 





ng

hi







 

 



  

    



        

 

             

                      

      

                                  

           

  

       

                                                                    

                                     

     

   

    

    

                                                                                                               



 

 



  

    







 

 

   

 



xs

Fi





et om 





ng

hi





 

 



  

    



         

 

             

                     

      

                                  

           

  

       

                                                                                                                  

                                                                       

     

   

    

    

                                                     



 

 



  

    





  



  











et om

xs

Fi

 







hi 

ng





 

 



  

    



          

 

             

      

      

               

           

                   

  

            

       

                                     

             

   

    

    

                                



 

 



  

    



  











    



Fi

xs





 

et om





ng

hi





 

 



  

    



                                     

                                    

           

          

  

                    

       

              

           

             

 

     

   

   

    

    

                                                                                                        





 

 



  

    



 





  

 

 





 



  



Fi



xs 





ng

hi

et om









 

 



  

    



         

 

             

      

      

               

           

            

  

                                                  

       

                                                     

                                                    

               

          

                 

        



      

       

       

 

 



  

    





ng

hi

et om

xs

Fi 



 

 



  

    



            

 

             

            

                  

  

       

                                                       

              

 

 

  

           

      

       

     

                                                                                                                



 

 



  

    





ng

hi

et om

xs

Fi 



 

 



  

    



            

 

             

          

                  

  

       

              

                                                                            

                                                     

    

      

       

     

                                                                                                                   



 

 



  

    





ng

hi

et om

xs

Fi 



 

 



  

    



               

 

          

      

                                

  

                                          

       

              

    

            

             

         

                                                       



 

 



   

    



         

             

                        

                         

 

                                             

            

                               



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

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



 

 



   

    



       

    

                                     

                 

                



                   



               



                     



                                



                     

                                                          

                         



            

                               

 

                             



                               

  





 

 



   

    



                                                    

    

                                                                                           

  





ng

hi

et om

xs

Fi



 

 



   

    



                                                                          

   

  

    

     

  

    

     

  

    

     

  

    

     

 



             

                                                          



                                    



 

 



   

  



     

 



                                                                                                        



                                         



                                                                                                                      

xs

  

Fi

                           

ng

hi

et om

                                  





 

 



  

    



                                               

                         



                                             

            

                                             



 

 



 

 



  

    



       

   

            

                

                       



                    



                   



               



                     



                                



                     

                                                          

                         



            

                                 

                             



                                                      



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                                                         





 

 



  



    

                                                                                                                                                







 

 



  

  



          

 



                                                                                                              



                                                



                                                                                                                            

Fi

  



ng

hi

et om

xs

                  



 

    



    







 

 



  

    



                                                                                                                                                                                                                                              

Fi

         

xs

                         

     

      

      

ng

hi

     

et om

 



 

 



  

    



       

                

                     

          

           

                    

             

          

      

 

 

  

                     

  

   

   

                                        







 

 



  

    



       

 

             

            

                    

                                                            

     

  

   

   

ng

hi

et om

xs

Fi 



 

 



  

    



        

                        

                                                               

                                                     

                               

                                                    

                         

              

 

 

                                

     

     

      

      



 

  





















 

 



  

    



         

 

                                                               





 

                         

              



                 



              





                       















                  

  

Fi xs







       

et om

                                                    

ng

hi



  

 

    

 

    

     

                                              



                        



                                                            



                                                    



 

 



  

    



     

               

                                                                      



                                            

                                            



                                     

                         

xs

Fi 

et om

                                        



ng

                

hi

                 

 

    

 

    

     

                                         



 

 



  

    



ng

hi

et om

xs

Fi 

 

 



  

    



                                             

 

 

 

 

                                                                             

 

             

                                                                                   

  

                   

  







                                     

 









 









 









 





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                  

 

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 

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                 

 

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                 

              

                 



 

 

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    

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    

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                                                   

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 

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 

                                                                

               

                                                                                                           

  

                                                                        

  

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              



 

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  

    

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  



    

                                                                                                                                                                                                                       



 

 



  

    



ng

hi

et om

xs

Fi 

 

    



    



                               

                    



                         



                  

 

              

                



      



    



               

                



                   

                                                      



             



        



    

    

                   



              



                          



                       



                          



                                 



                                    



 

 



  

    



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xs

Fi 



 

    



    



                            

                            



       



                     



   



              



                                 



                                    

                        

                                                           



                  



      



      

   



               



                   

                                                  



             



        



    

    

                   



              



                      



                  



                                   



 

 



  

    



ng

hi

et om

xs

Fi 

 

    



    



                                              

                                                                 

                       

                                       

                                

E

                                                                                           

B

F 11 

                                                                                        



 

 



  

    



ng

hi

et om

xs

Fi 



 

    



    



                               

                       



                



                                        



                      

                                 

    

                   



              



                     



                             



   



            



                



                  



                        



                    



                           



                                              



       

                                                        

       



                          



                 



   





      



                                      



    



     

 

 



  

    



ng

hi

et om

xs

Fi 

 

    



    



                           

                       

                                   

   



                





                     

                   



              



                     



                      



   



            







                            

                  



                

                    



                   

                                                 

                                                      

                                              



       

      

       



                          



                 



   





      



                                      



    



     

 

 



  

    



ng

hi

et om

xs

Fi 

 

    



    



                                                        

                



          



                   



   



            





                                   



                   



              



                     



                            

               



                

                    



                   



                                              



       

                                                        

       



                          



                 



   



      



                                      



    



     

   



 

Hydraulics

    

    



Stabiliser Check Valve (With Relief Valve) Relief Valve Pressure Testing

Dismantling and Assembly                      When Assembling

            C              A                      12  

            Torque Settings  1

 

  

  

ng

hi

et om

xs

Fi 

 

Hydraulics

    



    

Stabiliser Check Valve Dismantling and Assembly                      When Assembling             Torque Settings  1

 



  

  

 

 



  

    



    

  

                               

             

        

 

    

    

      

                

                                 

          

                                                

  

   

  

                         

          

            

           

ng

hi

et om

xs

Fi 

 

 



  

    



       

 

                             

       

                                                                     

                  

    

                      

                                                           





 

    

 

    





 

    

 

    

                                                                                                                                                                     

                                   



               



                              



 

 



  

  



  

  



                                               



              



                



                                          



 

 

 



  

  



  

  



    



                                 



                         



              



 

 

 



  

  



    

  



               



              



                  

                                                                                                                       



 

 



  



    

                                                   

                                                      

                            



                                                                              



 

 



  

    



       

 

 

       

                             

            

 

                  

                                                    

                           

             

                                        

   

   

                                    

                                         

               

                 

                                       











 

 



  

    



        

 

             

   

                                        

                             

  

 

  





 

    

 

    

                                                



                                 



                  



                           



                   



                           



                  



                           



                  



 

 



  

    



                                                                 

 

    

                                 

                                                               



 

                       

  



 

                                                    



                                          

 

             

  



 

 



  

    



                                                                                                                                                                         



                                                                                                                                              

  

   

   

                             



 

 



  

    



                                         

 

 

                               

  

 

                                                                                            



           

           

  



                                                                       





                                                              





                                 





 

 



  

    



                 

                             



       

         



              

 

 



                 

  





                                                         



                                      



                                

                               



                                  



                 



       

  

  

   

   

  









        









        





 

        





 



                                                                              



 

 



  



    

               

 

                                                    

                         

                                                                               



 

    



 

    

 

 



  

    



    

 

             

              

      

           

 

                 

          

            

                     

                          

 

                                 

                                                               

                           

                                               

                                                                                                                                                                                                  

  

   

   

                             



 

    

 

    

                                                         



                               



              



                                     



 

 



 







 

                                                                                        

       

        

     

                                                                



        

             

                 

           

   

  

                                   

                         

 



 





    

 

                       

                                     

                             

      

  

                                                                                                                                          



           

                                         

                                            

 

 





 

  

                                     







                                               

                                                                         



                            

                                  

 

                

 

 





 

  

                                                                                      

                                             

 

                              



                                      

 

 

 





  

 

                            



 

 

         

              

    

    

    

                  

                             

        

         

         

                    

                                   

           

           

           

                          

      

        

        

                               



                                                              

                        



 

 





  

 

  



              

                

                           

                    

     

                    

   



                            

                           



            

      

      

      

    

   

     

     

     

    

   

    

    

    

    

   

     

     

     







     





 

 





  

 

          

   

      

      

      

  

   

     

     

     

                

      

      

      

  

     

     

     

                

      

      

      

  

     

     

     

      

   

      

           

   

               

   

      

       

       

   

   

     

     

     

   

   

     

     

  

                                    



 

 





  

 

 



                         

             

                 

  

         

                          

                    

   



                             

                           



          

   

   

   

 

  

  

  

 

  

  

  

 

  

  

  







    

     

 



 

 





  

 

         

 

   

   

   

 

  

  

  

                       

      

                

           

   

   

   

   

  

  

  

   

   

   

  

  

  

               

 

   

    

    

 

  

  

  

 

  

  

  

 

  

  

  

                                     



 

 





  

 

                                                                     

    

   

  

 

   

 

 

 

 

 

   

 

 

 

 

 

     



  

   

        

 

       

 

 

 

     

 

        



 

  

  

  

 

 

 



  

    

 

                      

  

    

  

 





        

 

 

 

 

 

 

 

    

 

 

 

 

 

 

 

                                      



 

    



  

    

 

    



 

 

  

                                                                                  

                        

                                                                                                            



 

  



Transmission 

  

 

  



Transmission 

  

 

  

Transmission 

  

Synchromesh Description             SYNCHRO HUB (A)                                            C      D   SYNCHRO RINGS (B)                     BLOCKER PINS (C)                                                      SPLIT ENERGISER PINS (D)                                                SYNCHRO CUPS (E)      



Operation  F          B       E                      D          A                                                                                        G                                H                                                                   J

 

  



Transmission 

  

 

  



Transmission 

  

 

  



 

  

 

  



 

  

 

  



 

  

 

 







  

           

 

 

 

  

 

 

 



 







    

 

                                                        

        

 

 

 

  

 

 



 



 





     



 

  



 

  

 

 





  



            

 

 

 

  

 

 

 



 







    

 

                                                        

        

 

 

 

  

 

 

 



 



 

  

                                         



 

  



 

  

 

 







  

            

 

 

 

  

 

 

 



 



 

  

                

 

                                                    

        



 

 



  



 



 

 

     





  

            



 

 





  



              

 

 

 



 



 

 

 

 

                                             

 

 







 

  

Transmission 

  

Powershift Gearbox Clutch Operation                                                                        

2/4 Wheel Drive Operation                                                       



 

 

Transmission

  

    

 

Syncro Shuttle Gearbox                                              A

        

B

        

C

         

D

             

E

           

F

          

G

        

CHECK

ACTION

1

     

     

2

              

     

3

      

        

4

    

              

5

    

      

6

    

       

7

    

            

8

      

           

9

           

     

10

  

            

11

    

            

12

        

  



 

    

Transmission

    

 

Syncro Shuttle Gearbox (cont'd) CHECK

ACTION

14

     

               

15

     

       

16

    

                

17

      

     

18

               

    

19

        

            

20

       

         

21

       

         

22

    

         

23

                 

24

        

      

25

      

         

26

     

       

27

     

    

28

       

     

29

    

     

30

         

      



 

    

Transmission

    

 

Syncro Shuttle Gearbox (cont'd) CHECK

ACTION

33

      

    

34

       

        

35

        

        

36

    

      

37

      

              

38

    

          

39

       

      

40

        

             

41

      

              

42

     

     

43

    

      



 

    

Transmission

 

 

  

2/4 Wheel Drive Clutch 2WD Cannot be Engaged                                               

                                                         

Possible Cause

Remedy

7

7

  

          7.1             

           

7.2                                  8

      

8

8.1    

8.1          

8.2    

8.2          

8.3     

8.3  

8.4     

8.4     

8.5     

8.5                

8.6     

8.6         

8.7     9

8.7    

   9.1    9.2             

 

9

  9.1       9.2             

4WD Cannot be Engaged                                             

 

 



  

 

    

                                                                       

         

  

  

  

     

  

     

  

   

  

  

  

   

  

  

  

       



     

 

 



  

 

 

  

  



    



         

         

                        

                                                                 

    



   

           

   



    



                                                                               

       



  

                           

      

       



 

 

        

            

     



   

   

             

                        

    



  

            

       

     

 

      



  

          

    

  

    

       



 

      

      

  

                      

 



                              

        

         

                               

                                               

                                        

                                                          

                                                               

                    





 

    

Transmission

    

 

2/4 Wheel Drive Clutch (from Machine No. 415012) 4WD CANNOT BE ENGAGED                                           1

       

2

          

3

                

4 5

                                 

6

       

            

Possible Cause

Remedy

7

7

  

          7.1              7.2                                 

8

      

8

 

8.1    

8.1          

8.2     

8.2  

8.3     

8.3     

8.4     

8.4               



9

8.5     

8.5         

8.6    

8.6    

   9.1   



9

  9.1      

 

 

Transmission

  

    

 

2/4 Wheel Drive Clutch (from Machine No. 415012) (cont'd) 2WD CANNOT BE ENGAGED                        Possible Cause

Remedy

10

10

     

  Note:              

11

        

11

    Note:     

12

   



12

         

 

 



  

    



                                                        



                                                                 

    

     

     























 

 

 

    



  

    

 

 



  

    

 

                                    

                                                                 

        

                               

                            



                       

                                               

   

 



       



              



             



             



    



      



                   



         



    



                



                                

        



             



                





                             

  

   

   

 

 



  

    

 

    X

 

±5mm (0.197in) Front ±6mm (0.236in) Rear

                       

       

        



                                         



                                       



 



                              

          



                                           



                                           







 







                    



      



                           

 



 

  

 

    



    

 

      

                       

                                                      





                     

                   



 

                                        



 

                   





         





 

 



  

    

 

      

                       







                                      





                                 





                               

   

                                          





 

 



  

    

 

      

                                         

 

                     



                                                                                               







A

B



                          





            







 

 



  

 

    

      

                                            





      

             



             



                     



    





                      



    

                                         



                              



                       



   







 

    



Transmission  

    

 

 

Transmission

  

 

    

 Drive Head - Dismantling (All Wheel Steer Machines)

                     1

                 

2

          

3

        



 2 4

        1       2    

5

         

6

    3  4     5  6

7

    7  8

8

       9      

9

    10   

10

      11     12  13.

11

        14  15    

12

      16  17        B

13

      18     12.

14

    19     20      13.

15

        23       21   22.    

16

   24      2



 

Transmission

    

 

    

 Drive Head - Assembly (All Wheel Steer Machines) Pinion Depth Setting Procedure 1

     32    29                

2

  A                    

3

                                  

4

                        

5

                            

        A         

       





     

 

 



Note:                                                 



 

    



Transmission  

    

 

 

Transmission

  

Note 1                                               

13

5

      26   

14

                  5  6                 3  4

16

                              

 17

                                     3   

18

                 

19

          

20

     

     23         21   22 6.1    23    

6.3          30                                      23              6.4                     A



   5  6                        

15

        25   

6.2                          

    7  8   5  6

Note 2                  6.3      

        2 6

         

     2

  30   24

   24                             

    10    

  13

      31   

4

         

12

 29                     

   27      2

10

 2

      2    

3

    12     13                    11                    

11

  28      

2

9

  12

                   1

  

 

Drive Head - Assembly (All Wheel Steer Machines)

 



Note 3        

                                  

 

 

Transmission

  

 

    

 Drive Head - Assembly (All Wheel Steer Machines)

Crownwheel and Pinion Adjustment                                 

  

                             

                               



 

    

Transmission

    

 

Removal and Replacement (2 Wheel Drive Machines)                                                                               



  





 

Transmission

  

    

 

Dismantling and Assembly (2 Wheel Drive Machines) When Dismantling                                  24

   6  8          3                2. Torque Settings Item 3

Nm 

kgf m 

lbf ft 

9







11







         When Assembling   20  22             18               17          9  11              7



 

    



  

    

 

    



  

    

 

 



  

    

 

   

 

       

                                              

                              

              



 

                 



 

 

                          

         

 

        

 

             



                          



              



               



      



                   



         



    



               

                                         

   

    

    



             

       



      



 

 



  

    

 

    X

 

±5mm (0.197in) Front ±6mm (0.236in) Rear

                                                               

 

       

        



                                         



 

                                       

                              

          



                                           



                                           



                    



      



                           





 

 

 



 

  

 

    

Transmission

    

 

Renewing the Pinion Oil Seal                                   



  





 



 

  

  

  

 







 



  









 

  









 

 



  

    

     

   

             

                   

 

             

         

         

                                   

 

                                

         





                 



                                     



             



                



                                           

                    



               





 

    



Transmission   

    

 

Transmission

    

    

  

Removal and Replacement

13

                      J

14

      

      

 WARNING

    B  N

A raised and badly supported machine can fall on you. Position the machine on a firm, level surface. Before raising one end ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

15

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

16

                   M

17

         G          

18

       J.

19

           

20

              

        A           

 

Removal 1

                        

2

      

3

      

4

      P         

Note 1:                          

Replacement

5

    D

                             

6

      E

          

7

    F          L

                               

                   C

Torque Settings

8

9 10

11

        

                                 Q

       

Item E

Nm 

kgf m 

lbf ft 

F







J







K







P







Q







          H   

Note 2:                  



 

Transmission

    

  

    

Solenoid Valve Dismantling and Assembly                                  When Dismantling     2    3    4   5      6        A   7   8.     9  10   11   12                         When Assembling                          



 

    



    

  

    

    

                              







                    







        

                    

 

           

 



      



                    



      





   









 

    



    

  

     

                   



   



   

                



 





           



    



 

  

          

 



              

                        





                        

      

         









 

    



    

  

    

                    

     









           

 

                       





     



     

 



                  

                 

                           



          



            





                            



 





      







 

    



    

  

     

                                           

                                     





      

                   

 







     

               

   



      

  

                   









              



   

                    

 

                       



 

    



    

  

            





 

    



 

  

                                                               

  



 

                                              

                        



                           

 

               



       



        



                                    



         



                



                   





             

                      



      



                                            



                                            



             



                                                                               



           



      



      



                               

            

                          



          



        



   



         



       



                



 

    



    

  

               





                                                                                                                  



                



                                 



      

      

         



             



                           



                               



                            



                                          

 





 

    



   

    

 

    

   

    



                                                                      



                        



                               

                           



              



      





       



                                    

                                  



   



                     



                               



                                

                                                                                    





                                                 

              



        

             



             

                  



                





       

                                        



           



                               



                



                                 



      

                               

                    



              



            



 

 



  

  

    

                                                      

A

                                                                                                                                                                                                                                             

  



   

   

 

    



   

    

 

 



  

  

    

                                        



                                                                                   



                                                                  



                                                             



                                           



                        

                                

 

                                                                                                                                                                                                                     

                       

   

                                                    

              

                 





                                                 



                                 

                                                             

 

    

Transmission   

1

                 

2

            

    

                               CAUTION:                              



 

    



Transmission  

    

 

Transmission

    

12

                      J        

13

      

      

 WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface. Before raising one end ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine.  

    B  N 14

                        

2

      

3

      

4

      P         

Note 1:                           5

      E

6

    F   

7

                   C          M

9

10

        A       

15

         G          

16

       J

17

           

18

              

Removal

8

  

 

Removal and Replacement

1

 

Replacement                                                                                      

Torque Settings Item E

Nm 

kgf m 

lbf ft 

F







J







K







       

P







   H        

Q







                          Q

Note 2:                                          



 

    

Transmission  

    

Hydraulic 2/4 Wheel Drive Unit Dismantling and Assembly

 

                                                                                       

Torque Converter Removal and Replacement                     



 

    



    

 

                                                                

                                                                           



                                    

                                



              

 

 

   



   

       

   

   

                                                                                      

                          



                

                                                                          

                     

                  



 

 



  

    

 

                                   

     

   





 

   

   

   

   

                                                                                            

   

       

                                 

       

                                 

       

                                                                                                                       

                       

                



 





                                                                                      

                                    







  

    



    

 

                                                                                      

                     



                     



                       

                 

                

                                                                                      

 

                                             

      



                                



                      



  

    



    

 





 

 



  

 

 

  

                        

         

                             



                                       



            



       

             

                                                                

                 

                               

         

             



                                                           



            



     

 

                                              

   

                      

             

                       



                                                      



            



          

                                                                  



 

    

  

    

               

             



                                          



   

            

           



         

                                                          

                                         



                           



          

         

                     



                              



            



     



 

 



 





  



                     

  

          

 

   



 

  



                     

      

                                                            

     

            

     

 

 





  

  

 

   



            



      

               

             

   

         

   

  

   

 

 

    

            

                        



 

 



 

 





                         





                

      

 





  



               



  



  



   



          



   



                   



  



     



          



         



   



   



   



  



  



      



  



    



    



  





            







         

         

       





       



      



  



  



 



  



  



               



  



     



   



  



  



         



  



        



 



             





 

 

  

 









        

      

     

   



 

 

 



      

     



          

     



   



    



     



  



          

     



  



               



     



  



  



      



         



   



       

  



       

    



    



   



  



     



                                                               



    



        

           



        

                      





    



   

     

 

 

  

 



    

                            



          

 

  

 



              



    



    



                 

           



  



                     

                 



 

 



 

 





                                        



          



             

                      

 

                                  



       



         



                                

                                                           

                                    

                                                                                         





 

 



 

 

  

  

                                

                     

                                                                                                                                                                                      



                     





 

    



   

    

 

 



  

  

    

                                                                                                                                                                                

  

   

   

                



 

    

   

    







 

 



  

    

  

                       



                  

 



   

                                               



                         



                 



    

           



                                     

                                                                              

                     



                  

                      



    

           



                         



                                    



          

                   

         



 

 



  

 

       

  

   

   



     



      



        



          

                                                                             

                    



                     



                  

                      



                                    



         







 

 



  

    

       

   

   



            



            



              



           



            



        



          





                                              

                            

     





 

 



 



 

 



  

    

       

               

             



             



      



             



      



     



       

       



 

 



  

    

       

  

      

             

                                                     







  

 

 











 

 



 

    



     

    

 

 



  

    

    

                         







          

       



          

                 



                   

   





                        

                  

  

       



                 



              



                                      



                       

                                    

                



          



          



   



 

     

 

    



Brakes     

    

 

Brakes

    

    

    

Dismantling and Assembly                    When Dismantling   1   2            3                                         When Assembling

 WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.  

                                   3     5        A



 

 



 





  

   

  

  

    



  

 

 





  

 

                         

                                                                  

      



 







 



 





 



 

             

  

     

  

     

     

         

        

           

           



       

 

    



  

    

 

    

  

    

                                                                      

                                                

                                                                                                                           



 

 



  

    

  

 



 







 



 







 





 

    



 

  

  

                                        



          



            



           



                                      

                                     



                                  



    





         



               



         



              

                                                               



                     



    

  



                               



   



        



       



    



                



              



                                    

              

             





          



          



        

                         

                  



                        



             

  

    



    

  

      

 



       







                                                                                             



             



                                   

                                                                                                                                      



             

      



           

         

                      

                  



          



       



                           



                         



         



      



                      



        

      

       

       

                    

 