JCB 419S Wheel Loader Service Repair Manual Instant Download (SN 2439651 and up)

1
Foreword
SERVICE MANUAL LOADER 419S EN -
9813/6500 ISSUE 1 - 02/2017 This
manual contains original instructions, verified
by the manufacturer (or their authorized
representative). Copyright 7-02-20 JCB
SERVICE All rights reserved. No part of this
publication may be reproduced, stored in a
retrieval system, or transmitted in any form or
by any other means, electronic, mechanical,
photocopying or otherwise, without prior
permission from JCB SERVICE. www.jcb.com
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine
you do not understand.
Treat the Operator's Manual as part of the
machine. Keep it clean and in good condition.
Replace the Operator's Manual immediately if it
is lost, damaged or becomes unreadable.
Contents 01 - Machine
03 - Attachments, Couplings and Load Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating Conditioning (HVAC) 15
- Engine
and Air-
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products 78 - After Sales
2
15 - Engine 00 - Engine 00 - General
Clean Notice Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause
damage and possible failure of the
engine. Notice The engine and other components
could be damaged by high pressure washing
systems. Special precautions must be taken if
the machine is to be washed using a high
pressure system. Make sure that the alternator,
starter motor and any other electrical
components are shielded and not directly cleaned
by the high pressure cleaning system. Do not aim
the water jet directly at bearings, oil seals or
the engine air induction system.
Drain and Fill
Refer to Engine, Oil Filter, (PIL 15-21-00).

• Before carrying out any service procedures that
  require components to be removed, the engine must
  be properly cleaned.
• Cleaning must be carried out either in the area
  of components to be removed or, in the case of
  major work, or work on the fuel system, the
  whole engine and surrounding machine must be
  cleaned.
• Stop the engine and allow it to cool for at least
  one hour. DO NOT attempt to clean any part of
  the engine while it is running.
• Make sure that the electrical system is isolated.
• Make sure that all electrical connectors are
  correctly coupled. If connectors are open fit the
  correct caps or seal with water proof tape.
• Cover the alternator with a plastic bag to
  prevent water ingress.
• Seal the engine air intake, exhaust and breather
  system.
• Make sure that the oil filler caps and dipstick
  are correctly installed.
• Use a low pressure water jet and soft bristle
  brush to soak off caked mud or dirt.
• Apply an approved cleaning and degreasing agent
  with a brush. Obey the manufacturers
  instructions.
• Use a pressure washer to remove the soft dirt
  and oil. Important DO NOT aim the water jet
  directly at oil seals or electrical and
  electronic components such as ECU (Electronic
  Control Unit)'s, alternator or fuel injectors.
  DO NOT place the jet nozzle closer than 600mm
  (24 in) to any part of the engine or after
  treatment system including exhaust sensor ECU
  (if installed).

15 - 24
3
15 - Engine 00 - Engine 00 - General
Remove and Install Air Conditioning
Maintenance The air conditioning system is a
closed loop system and contains pressurised
refrigerant. No part of the system should be
disconnected until the system has been
discharged by a refrigeration engineer or a
suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.

1. When the pressure washing is complete move the
   machine away from the wash area, or
   alternatively, clean away the material washed
   from the machine.
2. Before working on specific areas of the engine
   use a compressed air jet to dry off any moisture.
   When the area is dry use a soft clean brush to
   remove any sand or grit particles that remain.
3. When removing components be aware of any dirt or
   debris that may be exposed. Cover any open ports
   and clean away the deposits before proceeding

Remove Remove the Engine, Transmission and Pump
Additional cleaning must be carried out prior to
working on the high pressure fuel system, refer
to Fuel System - Clean (PIL 18-00).

1. Make the machine safe. Refer to (PIL 01-03).
2. Install the articulation strut. Refer to (PIL
   06-27).
3. Disconnect the battery. Refer to (PIL 33-03).
4. Remove the operator station. Refer to (PIL
   09-00).
5. Remove the rear bodywork. Refer to (PIL 06-00).
6. Drain the cooling system. Refer to (PIL 21-00).
7. Remove the propshafts. Refer to (PIL 27-47).
8. Remove the centre undershield. Refer to (PIL
   06-06).
9. Remove the SCR (Selective Catalytic Reduction)
   unit. Refer to (PIL 18-30).

• Disconnect the electrical connector from the gear
  pump. Refer to (PIL 30-11).
• Disconnect the hydraulic hoses from the gear
  pump. Refer to (PIL 30-11).
• Figure 154.

A
A Hydraulic hoses
15 - 24
4
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5
15 - Engine 00 - Engine 00 - General
12. Disconnect the hoses from the emergency steer
pump. Figure 155.

• Remove the fuel filter assembly from the
  machine.
• Remove the water separator from the engine.
• Figure 157.

K
B
H
M
B
J

• H Fuel hoses
• Fuel filter assembly
• Water separator
• M HVAC (Heating Ventilation Air Conditioning)
  compressor
• 22. Disconnect the HVAC hoses from the HVAC
  compressor.

• B Hydraulic hoses
• Loosen the clip.
• Disconnect the suction hose from the main
  hydraulic pump.
• Remove the bolts 1.
• Disconnect the hydraulic hoses from the main
  hydraulic pump.
• Disconnect the electrical connector from the
  main hydraulic pump.
• Figure 156.
• C
• C

23. Disconnect the cooler transmission. Figure
158.
hoses from the
N
G E
N
C
F D

• N Cooler hoses
• Disconnect the electrical cables from the starter
  motor.
• Disconnect the electrical connector from the oil
  level sensor.
• Disconnect the engine earth cable from the
  chassis.

• Hydraulic hoses
• Suction hose
• Bolts 1
• Clip
• Electrical connector
• Disconnect the fuel hose from the fuel filter
  assembly.
• Remove the bolts 2 (x2).

6
15 - Engine 00 - Engine 00 - General

• Support the engine and transmission with
  suitable lifting equipment.
• Remove the engine from the front engine mount.
  Refer to (PIL 15-63).
• Remove the bolts 5 (x8) and nuts 3 (x8) from the
  transmission mount.
• Figure 159.

Figure 160. V W
X

• V Bolt 6 (x4) W Washer (x4) X Pump
• Remove the bolts 7, cover plate and plastic
  cover.
• Use a suitable tool to turn the flywheel to get
  access to the components.
• Remove the flywheel to the flexible coupling
  bolts (x4) through the cut-out in the case.
• Figure 161.

AJ
AK AJ Bolt 5 AK Nut 3

1. Carefully lift the engine and transmission
   assembly from the machine.
2. Make sure that all the connectors are released.

AA
AB
Separate the Transmission, Engine and Pump
Assembly
Y

1. Mount the engine, transmission and pump assembly
   on a suitable stand.
2. Support the pump.
3. Remove the mounting bolts 6 (x4) and washers
   (x4).
4. Remove the pump from the transmission system.

Z

1. Bolts 7
2. Cover plate

• AA Plastic cover
• AB Flexible coupling bolts (x4)
• Remove the bolts 8.
• Connect the lifting eye to the transmission case.

1. Tighten the bolts 8 to the correct torque value.
2. Connect suitable lifting equipment to the lifting
   eyes (x3).
3. Support the weight of the transmission.
4. Remove the bolts 9 (x12).
5. Remove the transmission from the engine.

7
15 - Engine 00 - Engine 00 - General
Figure 162. AD AC AE
AF

• AC Bolts 8
• AD Lifting eye (x3) AE Bolts 9 (x12) AF
  Transmission
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the bolts to the correct torque value.
• Table 68. Torque Values

Item Nm
AB 44
AE 43
8
15 - Engine 12 - Crankshaft 27 - Damper
27 - Damper Remove and Install
Figure 164.
Remove
6
1

• Make the machine safe. Refer to (PIL 01-03).
• Make sure that the engine is safe to work on. If
  the engine has been running, make sure the
  engine has cooled sufficiently before you start
  the removal.
• Remove the engine drive belt. Refer to (PIL
  15-18).
• Support the damper.
• Remove the screws (x6).
• Remove the damper from the engine.
• Figure 163.

4
3
2
5
Table 69. Torque Values
Description Torque Values
- first stage torque 50Nm
- second stage torque 90
A
B

• Damper
• Screws (x6)
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the screws to the correct torque value.
• Use the torque and angle tightening procedure.
  Refer to (PIL 72-00).
• Make sure that you follow the correct tightening
  sequence. Refer to Figure 164.

15 - 31
15 - 31
9
15 - Engine 18 - Engine Belt 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-33 Health and Safety
..........................................
15-34 Component Identification ...................
............ 15-34
A crankshaft pulley is used to drive a FEAD
(Front End Accessory Drive) belt. The belt drives
the coolant pump. Depending on the machine
application, the belt is configured to drive
engine mounted accessories, such as the
alternator, cooling fan and air conditioning
compressor.
Some applications have a second pulley on the
crankshaft which drives a dedicated fan belt. The
belt drives an engine mounted cooling fan.
15 - 33
10
15 - Engine 18 - Engine Belt 00 - General
Health and Safety Turning the Engine Do not try
to turn the engine by pulling the fan or fan
belt. This could cause injury or premature
component failure. WARNING! The engine has
exposed rotating parts. Switch off the engine
before working in the engine compartment. Do not
use the machine with the engine cover
open. Notice A drive belt that is loose can
cause damage to itself and/or other engine parts.
Component Identification
Figure 165.
D
B
E
C G F
H
A

1. Crankshaft pulley
2. Fan pulley
3. Water pump pulley
4. Compressor installation location
5. Alternator pulley
6. Belt tensioner pulley
7. Belt tensioner
8. Vibration rubber damper

15 - 33
11
15 - Engine 18 - Engine Belt 03 - Drive Belt
03 - Drive Belt
Introduction
Introduction .....................................
............... 15-35 Health and Safety
..........................................
15-36 Check (Condition) ..........................
................ 15-36 Adjust ....................
........................................ 15-37
Remove and Install ...............................
........ 15-37
The crankshaft pulley is used to drive the
coolant pump via a FEAD (Front End Accessory
Drive) belt. In addition to the coolant pump the
drive belt can also be configured to drive the
engine mounted accessories.
The belt is maintained at a constant tension by a
spring loaded tensioner. To achieve the
necessary belt/pulley contact area the belt is
routed around idler wheels as required. The
configuration varies depending on the
accessories installed.
15 - 33
12
15 - Engine 18 - Engine Belt 03 - Drive Belt
Health and Safety Notice A drive belt that is
loose can cause damage to itself and/or other
engine parts.
Check (Condition)
At the recommended service interval, visually
inspect the drive belt for damage.

• Make the machine safe. Refer to Safety (Page
  01-1).
• Stop the engine and let it cool down.
• Renew the drive belt if it has cracks or if it is
  frayed or has pieces of material missing.
• Figure 166.
• B
• A

• C
• Crack in belt
• Missing piece of belt
• Frayed belt

15 - 33
13
15 - Engine 18 - Engine Belt 03 - Drive Belt
Adjust
Remove and Install
Adjustment is not possible with this drive belt.
A spring loaded tensioning unit ensures that the
FEAD (Front End Accessory Drive) belt is kept at
the correct tension.
There are a number of drive belt routes. This
procedure does not include all of the routes. Do
a diagram of the drive belt route before removal
to help installation.

• The belt tensioner is spring-loaded, it must be
  pivoted away from the drive belt. Do not pivot
  the belt tensioner in the wrong direction, this
  can cause damage.
• Make a note that too much force in the opposite
  direction of wind-up or when the belt tensioner
  is wound-up to the positive-stop, can cause the
  tensioner arm to crack or break.
• Remove
• Make the machine safe. Refer to (PIL 01-03).
• Isolate the battery. Refer to (PIL 33-03).
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Hold the tensioner against the spring force and
  lift the belt off the drive tensioner pulley.
• Figure 167.

D
B
E
C G F
H
A

1. Crankshaft pulley
2. Fan pulley
3. Water pump pulley
4. Compressor installation location
5. Alternator pulley
6. Belt tensioner pulley
7. Belt tensioner
8. Vibration rubber damper

15 - 33
14
15 - Engine 18 - Engine Belt 03 - Drive Belt

• Install
• Use the diagram to correctly route the new drive
  belt on the pulleys.
• Pivot the belt tensioner in the direction of the
  spring tang.
• Install the new drive belt. Put the drive belt
  over the water pump pulley last.
• If it is difficult to install the drive belt, do
  as follows
• Put the drive belt over the grooved pulleys
  first.
• Hold the belt tensioner up and slide the drive
  belt over the water pump pulley.
• Slowly release the belt tensioner to apply
  tension to the drive belt.
• Check the alignment of the drive belt with the
  belt tensioner and the other components.
• Use the deflection method to measure the tension
  in the drive belt.
• Apply the specified force between the pulleys on
  the drive belt.
• Force 110N
• If the deflection is more than the thickness of
  one drive belt per foot of pulley centre
  distance, adjust the drive belt tension.
• If there is too much movement of the drive belt,
  replace it.
• Close the engine compartment cover. Refer to
  (PIL 06-06).
• Run the engine and listen to hear if the drive
  belt squeals.
• Too much squeal indicates that the drive belt is
  slipping too much.
• Check the route of the drive belt to make sure
  it is correctly installed over each pulley.

15 - 33
15
15 - Engine 18 - Engine Belt 21 - Tensioner

• 21 - Tensioner
• Remove and Install
• Remove
• Make the machine safe. Refer to (PIL 01-03).
• Open the engine compartment cover. Refer to (PIL
  06-06).
• Remove the engine drive belt. Refer to (PIL
  15-18).
• Remove the capscrew.
• Remove the belt tensioner from the engine.
• If necessary, remove the bracket.
• Figure 168.

A
B

• Belt tensioner
• Capscrew
• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Tighten the capscrew to the correct torque value.
• Table 70. Torque Values

Item Nm
B 43
15 - 33
16
15 - Engine 63 - Mount 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-61 Remove and Install
....................................... 15-62
Engine mounts support the engine and in some
cases the transmission, they dampen noise and
vibration. The mounts isolate the engine and
transmission from the chassis so that vibrations
and noise are not transmitted to the rest of the
machine.
Most engine mounts consist of metal attachment
plates and large rubber insulator blocks. The
rubber portions of the mount are flexible and
provide the cushioning that dampens the engine
vibrations. The metal bracket part of the mount
provides the mechanical support and attachment
points for the engine mounts.
15 - 61
17
15 - Engine 63 - Mount 00 - General
Remove and Install
Consumables

1. Make sure that the engine is safe to work on. If
   the engine has been running, let it cool before
   you start the service work.
2. Support the engine with suitable lifting
   equipment.
3. Remove the engine front mount from the machine
   as follows

Description Part No. Size
Waxoyl 4004/0501A 0.4L
Waxoyl 4004/0502 5L
Waxoyl 4004/0505 200L
Remove 1. Make the machine safe. Refer to (PIL
01-03).
Figure 179.
F
W
V
A
X
E
B
X
V F
Y
C D

• A Engine
• C Mounting bracket (x2)
• E Mount (x2)
• V Washer 1 (x4)
• X Washer 2 (x4)
• Remove the bolt 1 (x6).
• Remove the locknut 1 (x4) and washer 1 (x4) from
  the engine mount.
• Remove the bolt 2 (x2), locknut 2 (x2) and
  washer (x4).

B Bolt 1 (x6) D Chassis F Locknut 1 (x4) W Bolt 2
(x2) Y Locknut 2 (x2) 4.4. Remove chassis.
the engine mount from the
5. Remove the engine rear mount from the
machine as follows
15 - 61
18
15 - Engine 63 - Mount 00 - General
Figure 180.
K
U
L
G
S
R
J
H Q
P
N
T M

• G Rear mount plate J Locking plate (x2) L
  Washer 3 (x2)
• N Bolt 4 (x4)
• Q Locknut 4 (x8)
• S Overload washer
• U Boss
• Remove the setscrews (x8) and locknut 4 (x8).
• Lift the engine and transmission assembly away
  from the machine. Refer to (PIL 15-00).
• Use a suitable stand to support the engine and
  transmission assembly.
• Remove the bolt 3 (x2), locknut 3 (x2) and
  washers 3 (x2).

H Resilient mount K Bolt 3 (x2) M Locknut 3 (x2)
P Washer 4 (x4) R Setscrew (x8) T Rebound washer

1. Remove the rebound washer, resilient mount and
   overload washer.
2. Remove the bolt 4 (x4), washers 4 (x4) and
   locking plate (x2).
3. Collect the boss (x4).
4. Remove the rear mount plate from the
   transmission.

15 - 61
19
15 - Engine 63 - Mount 00 - General

• Install
• The installation procedure is the opposite of the
  removal procedure. Additionally do the following
  step.
• Apply locking fluid to the bolt 3 before
  installation. Consumable Waxoyl
• Tighten the nuts to the correct torque value.
• Apply Waxoyl to the bolt 4 after you tighten it.
• Table 72. Torque Values

Item Nm
B 74
F 74
K 360
N 520
R 43
W 74
15 - 61
20
21 - Cooling System 05 - Fan Motor 00 - General
Disassemble and Assemble
Consumables

1. Mark the gear housing, front housing and rear
   housing to make sure of correct alignment when
   you assemble the fan motor.
2. Hold the fan motor in a vice on the housing, with
   the driveshaft pointing downwards. Use the vice
   soft-jaws to protect the housing.
3. Loosen the bolts (x4) and remove the fan motor
   from the vice.
4. Remove the bolts (x4), washers (x4) and the rear
   housing.
5. Remove the gear housing carefully and keep on a
   clean work bench.
6. Remove the rear bearing block, idler shaft and
   the driveshaft gear.
7. Remove the front bearing block.
8. Turn the housing over, with the shaft seal
   upwards, and remove the retaining circlip and the
   shaft seal.

Description Part No. Size
Surface Cleaning Fluid 4103/1204 1L

• Before you remove or disassemble the motor, make
  sure that its performance is as specified in
  technical data. If necessary replace the fan
  motor.
• Refer to General (Page 21-21).
• If any of the components are not suitable for use
  then replace the complete fan motor.
• If the output of the fan motor is satisfactory
  but there is an evidence of external leakage,
  disassemble the fan motor and replace the seals.
• Make sure that the external body of the fan motor
  and the work area is thoroughly cleaned and free
  from contamination.
• Put a plug on all the ports and wash the exterior
  of the fan motor with a proper cleaning solvent
  before you disassemble the fan motor.
• Consumable Surface Cleaning Fluid

1. If necessary, remove the proportional relief
   valve cartridge.
2. Clean all of the sealant from the mating
   surfaces. Consumable Surface Cleaning Fluid
3. Discard all the seals and O-rings.

Uni-Directional Motor Refer to Figure 223.
Disassemble 1. Remove the port plugs and drain
the oil from the motor.
21 - 27
21 - 27
21
21 - Cooling System 05 - Fan Motor 00 - General
Figure 223. Uni-Directional Motor C
D
E
F
A
G
B
J H
H L
R
N
K
T
E
M
D
P
S U
Q
V W
A Circlip C Front housing E E-seal G O-ring1 J
Gear housing L Idler gear N Rear bearing block Q
Proportional relief valve cartridge S Spring U
Valve seat W Bolt
B Seal D Back-up ring F Front bearing block H
Locating dowels K O-ring2 M Driveshaft gear P
Rear housing R Measuring coupling T Ball V Washer
21 - 28
22
21 - Cooling System 05 - Fan Motor 00 - General
Inspection

1. Apply a layer of petroleum jelly to the grooves
   in the bearing blocks, E-seals (x2) and back-up
   seals (x2). This will keep the seals in place.
2. Keep the E-seals, flat side outwards, into the
   front and rear bearing blocks. Carefully put the
   backup seals with the flat side outwards, in the
   respective groove made by the E-seal and the
   groove in the bearing block.
3. Make sure that the notches in the back-up seals
   and E-seals are lined up, so that the back-up
   seal sits flush with the E-seal.
4. Keep the front housing, with the seal side facing
   downwards on a clean flat surface.
5. Apply a thin layer of petroleum jelly to the
   exposed face of the front bearing block.

• Clean and dry all the parts before you do an
  inspection.
• Inspect all O-ring grooves and shaft seal
  recesses and make sure that there are no burrs.
• Inspect the driveshaft for damage. Check for
  marks or grooves on the driveshaft in the area
  of the seal. Slight discolouration of the shaft
  is permitted.
• Inspect the faces of the gears for scoring or
  excessive wear. If the face of the gear is sharp,
  it can damage the bearing block. If you find any
  signs of wear, replace the parts.
• Inspect the bearing blocks for excessive wear or
  scoring on the surfaces that are in contact with
  the gears.
• Inspect the bearing for excessive wear or
  damage.
• Inspect the area inside the gear housings. It is
  normal for the surface inside the gear housing
  to show a clean wipe on the surface of the
  intake side. There should not be excessive wear
  or scoring.
• Replace the fan motor, if you find any of the
  following defects
• The gear cut-in track on the low pressure side
  of the body is deeper than the specified or has
  a scarred and matt appearance.
• Dimension 0.08mm
• The PTFE (Polytetrafluoroethylene) coated
  bearings in the body or flanges are worn through
  so that the bronze base is visible.
• The gear side faces or bearing blocks are
  scarred.
• The driveshaft has a wear groove where the shaft
  seal lips run.

1. Insert the drive end of the driveshaft through
   the front bearing block with the seal side down,
   and the open side of the E-seal pointing to the
   intake side of the motor.
2. Install a sleeve over the driveshaft threads to
   protect the shaft seal. Slide the driveshaft
   carefully through the seal and then remove the
   sleeve from the driveshaft.
3. Install the idler gear shaft into the remaining
   position in the bearing block.
4. Apply a thin layer of clean hydraulic oil to the
   face of the driveshaft and idler gears.
5. Keep the rear bearing block on the driveshaft and
   idler gear shafts with the seals facing upwards
   and the open ends of the E-seals facing the
   intake side of the motor.
6. Make sure that the dowel pins are in place in
   the gear housing. On later housings there are
   two long dowels through the housing that locate
   in the front mounting flange and the rear cover.
   These replace the four short dowels.
7. Apply a layer of petroleum jelly to the seal
   grooves in both sides of the gear housing.
8. Apply a thin layer of petroleum jelly on the O-
   ring1 and O-ring2 and install them in the gear
   housing.
9. Move the gear housing downward over the rear
   bearing block until the dowel pins come in
   contact with their respective bores in the front
   housing.
10. Press the housing together with your hands. Do
    not force or use any tool.
11. Make sure that the intake port in the housing is
    on the same side as the open end of the rear E-
    seal and that the marks made on the housing are
    aligned.

Assemble

1. Wash all the components in a suitable aromatic
   solvent. When dry apply hydraulic fluid
   immediately to prevent moisture collecting.
2. Install a new shaft seal into the front housing,
   with the part number of the seal facing outwards.
   Press the new seal into its bore until it fully
   seats.
3. Install the circlip into its groove in the front
   housing.
4. Keep the front and rear bearing blocks on a
   clean work bench with the E-seal grooves facing
   upwards.

21 - 28
23
21 - Cooling System 05 - Fan Motor 00 - General

1. The surface of the rear bearing block should be
   slightly below the face of the gear housing. If
   the bearing block sits higher than the rear face
   of the housing then the E-seal or O-ring may
   have become detached from its seat and maybe
   trapped. Remove the housing and check the seals
   for correct installation.
2. Install the rear housing onto the dowels in the
   housing. Make sure that the marks made on the
   housing are aligned and press the housing
   together with hand pressure only.
3. Install the bolts (x4) and washers (x4).
4. Hold the fan motor in the vice on the housing,
   with the driveshaft pointing downwards. Use a
   soft- jaw vice to protect the housing.
5. Tighten the bolts to the correct torque value.
   Refer to Table 87.
6. Remove the fan motor from the vice.
7. Put a small amount of clean hydraulic oil in the
   inlet of the motors and rotate the driveshaft
   away from the inlet by one revolution. If the
   driveshaft binds, disassemble the motor and
   check for assembly problems. Rectify the
   problems and assemble the motor again.
8. If removed, install the proportional relief valve
   cartridge. Tighten it to the correct torque
   valve. Refer to Table 87.

Bi-Directional Motor Refer to Figure 224.
Disassemble

1. Remove the port plugs and drain the oil from the
   motor.
2. Mark the solenoid operated control valve, gear
   housing and front housing to make sure of correct
   alignment when you assemble the fan motor.
3. Hold the fan motor in the vice on the housing,
   with the driveshaft pointing downwards. Use a
   soft jaw vice to protect the housing.
4. Loosen the bolts (x4) and remove the fan motor
   from the vice.
5. Remove the bolts (x4), washers (x4) and the
   solenoid operated control valve.
6. Remove the gear housing carefully and keep on a
   clean work bench.
7. Remove the rear bearing block, idler shaft and
   the driveshaft gear.
8. Remove the front bearing block.
9. Turn the housing over, with the shaft seal
   upwards, and remove the retaining circlip and the
   shaft seal.

1. If necessary, remove the proportional relief
   valve cartridge.
2. Clean all sealant from the mating surfaces.
   Consumable Surface Cleaning Fluid
3. Discard the seals and O-rings.

Table 87. Torque Values
Item Description Nm
Q Proportional re- lief valve car- tridge 40
W Bolt 56
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21 - Cooling System 05 - Fan Motor 00 - General
Figure 224. Bi-Directional Motor C D E
A
F
B
G H
H K
P
M
D
J
L
R Q
N
A Circlip C Front housing E Front bearing block G
Gear housing J O-ring2 L Driveshaft gear N
Solenoid operated control valve Q Bolt
B Shaft seal D Seal F O-ring1 H Locating dowels K
Idler gear M Rear bearing block P Proportional
relief valve cartridge R Washer
21 - 31
9813/6500-1
21 - 31
26
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