This service manual provides instructions for maintenance and repair of a JCB 419S loader. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical systems, and various components. The engine section provides detailed instructions for maintenance tasks such as draining and filling fluids, cleaning, removing and installing the engine, transmission and hydraulic pump. It also includes sections for specific engine components and systems.

1. 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
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
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 and Air-
Conditioning (HVAC)
15 - Engine
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
15 - 24 9813/6500-1 15 - 24
Drain and Fill
Refer to Engine, Oil Filter, (PIL 15-21-00).
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.
Before carrying out any service procedures that
require components to be removed, the engine must
be properly cleaned.
Cleaning must be carried out either in the area of
components to be removed or, in the case of major
work, or work on the fuel system, the whole engine
and surrounding machine must be cleaned.
Stop the engine and allow it to cool for at least one
hour. DO NOT attempt to clean any part of the engine
while it is running.
1. Make sure that the electrical system is isolated.
2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical 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).

3. 15 - Engine
00 - Engine
00 - General
15 - 25 9813/6500-1 15 - 25
9. When the pressure washing is complete move
the machine away from the wash area, or
alternatively, clean away the material washed
from the machine.
10. 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.
11. 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
Additional cleaning must be carried out prior to
working on the high pressure fuel system, refer to:
Fuel System - Clean (PIL 18-00).
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.
Remove
Remove the Engine, Transmission and
Pump
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).
10. Disconnect the electrical connector from the gear
pump. Refer to (PIL 30-11).
11. Disconnect the hydraulic hoses from the gear
pump. Refer to (PIL 30-11).
Figure 154.
A
A Hydraulic hoses

4. 15 - Engine
00 - Engine
00 - General
15 - 26 9813/6500-1 15 - 26
12. Disconnect the hoses from the emergency steer
pump.
Figure 155.
B
B
B Hydraulic hoses
13. Loosen the clip.
14. Disconnect the suction hose from the main
hydraulic pump.
15. Remove the bolts 1.
16. Disconnect the hydraulic hoses from the main
hydraulic pump.
17. Disconnect the electrical connector from the
main hydraulic pump.
Figure 156.
F
C
C
C
E
G
D
C Hydraulic hoses
D Suction hose
E Bolts 1
F Clip
G Electrical connector
18. Disconnect the fuel hose from the fuel filter
assembly.
19. Remove the bolts 2 (x2).
20. Remove the fuel filter assembly from the
machine.
21. Remove the water separator from the engine.
Figure 157.
J
K
M
H
H Fuel hoses
J Fuel filter assembly
K Water separator
M HVAC (Heating Ventilation Air Conditioning)
compressor
22. Disconnect the HVAC hoses from the HVAC
compressor.
23. Disconnect the cooler hoses from the
transmission.
Figure 158.
N
N
N Cooler hoses
24. Disconnect the electrical cables from the starter
motor.
25. Disconnect the electrical connector from the oil
level sensor.
26. Disconnect the engine earth cable from the
chassis.

5. 15 - Engine
00 - Engine
00 - General
15 - 27 9813/6500-1 15 - 27
27. Support the engine and transmission with
suitable lifting equipment.
28. Remove the engine from the front engine mount.
Refer to (PIL 15-63).
29. Remove the bolts 5 (x8) and nuts 3 (x8) from the
transmission mount.
Figure 159.
AJ
AK
AJ Bolt 5
AK Nut 3
30. Carefully lift the engine and transmission
assembly from the machine.
31. Make sure that all the connectors are released.
Separate the Transmission, Engine and
Pump Assembly
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.
Figure 160.
V
X
W
V Bolt 6 (x4)
W Washer (x4)
X Pump
5. Remove the bolts 7, cover plate and plastic
cover.
6. Use a suitable tool to turn the flywheel to get
access to the components.
7. Remove the flywheel to the flexible coupling bolts
(x4) through the cut-out in the case.
Figure 161.
Y
Z
AA
AB
Y Bolts 7
Z Cover plate
AA Plastic cover
AB Flexible coupling bolts (x4)
8. Remove the bolts 8.
9. Connect the lifting eye to the transmission case.
10. Tighten the bolts 8 to the correct torque value.
11. Connect suitable lifting equipment to the lifting
eyes (x3).
12. Support the weight of the transmission.
13. Remove the bolts 9 (x12).
14. Remove the transmission from the engine.

6. 15 - Engine
00 - Engine
00 - General
15 - 28 9813/6500-1 15 - 28
Figure 162.
AD
AC
AE
AF
AC Bolts 8
AD Lifting eye (x3)
AE Bolts 9 (x12)
AF Transmission
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the bolts to the correct torque value.
Table 68. Torque Values
Item Nm
AB 44
AE 43

7. 15 - Engine
12 - Crankshaft
27 - Damper
15 - 31 9813/6500-1 15 - 31
27 - Damper
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. 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.
3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Support the damper.
5. Remove the screws (x6).
6. Remove the damper from the engine.
Figure 163.
A
B
A Damper
B Screws (x6)
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the screws to the correct torque value.
2.1. Use the torque and angle tightening
procedure. Refer to (PIL 72-00).
2.2. Make sure that you follow the correct
tightening sequence. Refer to Figure 164.
Figure 164.
6
4
25
3
1
Table 69. Torque Values
Description Torque Values
- first stage torque 50N·m
- second stage torque 90°

8. 15 - Engine
18 - Engine Belt
00 - General
15 - 33 9813/6500-1 15 - 33
00 - General
Introduction .................................................... 15-33
Health and Safety .......................................... 15-34
Component Identification ............................... 15-34
Introduction
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.

9. 15 - Engine
18 - Engine Belt
00 - General
15 - 34 9813/6500-1 15 - 34
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.
A
F
D
E B
C
H
G
A Crankshaft pulley
B Fan pulley
C Water pump pulley
D Compressor installation location
E Alternator pulley
F Belt tensioner pulley
G Belt tensioner
H Vibration rubber damper

10. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 35 9813/6500-1 15 - 35
03 - Drive Belt
Introduction .................................................... 15-35
Health and Safety .......................................... 15-36
Check (Condition) .......................................... 15-36
Adjust ............................................................ 15-37
Remove and Install ....................................... 15-37
Introduction
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.

11. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 36 9813/6500-1 15 - 36
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.
1. Make the machine safe.
Refer to: Safety (Page 01-1).
2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 166.
A
B
C
A Crack in belt
B Missing piece of belt
C Frayed belt

12. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 37 9813/6500-1 15 - 37
Adjust
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.
Remove and Install
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
1. Make the machine safe. Refer to (PIL 01-03).
2. Isolate the battery. Refer to (PIL 33-03).
3. Open the engine compartment cover. Refer to
(PIL 06-06).
4. Hold the tensioner against the spring force and
lift the belt off the drive tensioner pulley.
Figure 167.
A
F
D
E B
C
H
G
A Crankshaft pulley
B Fan pulley
C Water pump pulley
D Compressor installation location
E Alternator pulley
F Belt tensioner pulley
G Belt tensioner
H Vibration rubber damper

13. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 38 9813/6500-1 15 - 38
Install
1. Use the diagram to correctly route the new drive
belt on the pulleys.
2. Pivot the belt tensioner in the direction of the
spring tang.
3. Install the new drive belt. Put the drive belt over
the water pump pulley last.
4. If it is difficult to install the drive belt, do as follows:
4.1. Put the drive belt over the grooved pulleys
first.
4.2. Hold the belt tensioner up and slide the
drive belt over the water pump pulley.
5. Slowly release the belt tensioner to apply tension
to the drive belt.
6. Check the alignment of the drive belt with the belt
tensioner and the other components.
7. Use the deflection method to measure the
tension in the drive belt.
7.1. Apply the specified force between the
pulleys on the drive belt.
Force: 110N
7.2. If the deflection is more than the thickness
of one drive belt per foot of pulley centre
distance, adjust the drive belt tension.
7.3. If there is too much movement of the drive
belt, replace it.
8. Close the engine compartment cover. Refer to
(PIL 06-06).
9. Run the engine and listen to hear if the drive belt
squeals.
9.1. Too much squeal indicates that the drive
belt is slipping too much.
9.2. Check the route of the drive belt to make
sure it is correctly installed over each pulley.

14. 15 - Engine
18 - Engine Belt
21 - Tensioner
15 - 39 9813/6500-1 15 - 39
21 - Tensioner
Remove and Install
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Remove the capscrew.
5. Remove the belt tensioner from the engine.
6. If necessary, remove the bracket.
Figure 168.
A
B
A Belt tensioner
B Capscrew
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the capscrew to the correct torque value.
Table 70. Torque Values
Item Nm
B 43

15. 15 - Engine
63 - Mount
00 - General
15 - 61 9813/6500-1 15 - 61
00 - General
Introduction .................................................... 15-61
Remove and Install ....................................... 15-62
Introduction
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.

16. 15 - Engine
63 - Mount
00 - General
15 - 62 9813/6500-1 15 - 62
Remove and Install
Consumables
Description Part No. Size
4004/0501A 0.4L
4004/0502 5L
Waxoyl
4004/0505 200L
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. 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.
3. Support the engine with suitable lifting
equipment.
4. Remove the engine front mount from the
machine as follows:
Figure 179.
A
W
X
B
D
C
Y F
V
E
V
F
X
A Engine B Bolt 1 (x6)
C Mounting bracket (x2) D Chassis
E Mount (x2) F Locknut 1 (x4)
V Washer 1 (x4) W Bolt 2 (x2)
X Washer 2 (x4) Y Locknut 2 (x2)
4.1. Remove the bolt 1 (x6).
4.2. Remove the locknut 1 (x4) and washer 1
(x4) from the engine mount.
4.3. Remove the bolt 2 (x2), locknut 2 (x2) and
washer (x4).
4.4. Remove the engine mount from the
chassis.
5. Remove the engine rear mount from the machine
as follows:

17. 15 - Engine
63 - Mount
00 - General
15 - 63 9813/6500-1 15 - 63
Figure 180.
K
L U
G
Q
H
R
M
S
T
J
N
P
G Rear mount plate H Resilient mount
J Locking plate (x2) K Bolt 3 (x2)
L Washer 3 (x2) M Locknut 3 (x2)
N Bolt 4 (x4) P Washer 4 (x4)
Q Locknut 4 (x8) R Setscrew (x8)
S Overload washer T Rebound washer
U Boss
5.1. Remove the setscrews (x8) and locknut 4
(x8).
5.2. Lift the engine and transmission assembly
away from the machine. Refer to (PIL
15-00).
5.3. Use a suitable stand to support the engine
and transmission assembly.
5.4. Remove the bolt 3 (x2), locknut 3 (x2) and
washers 3 (x2).
5.5. Remove the rebound washer, resilient
mount and overload washer.
5.6. Remove the bolt 4 (x4), washers 4 (x4) and
locking plate (x2).
5.7. Collect the boss (x4).
5.8. Remove the rear mount plate from the
transmission.

18. 15 - Engine
63 - Mount
00 - General
15 - 64 9813/6500-1 15 - 64
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Apply locking fluid to the bolt 3 before installation.
Consumable: Waxoyl
3. Tighten the nuts to the correct torque value.
4. 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

19. 21 - Cooling System
05 - Fan Motor
00 - General
21 - 27 9813/6500-1 21 - 27
Disassemble and Assemble
Consumables
Description Part No. Size
Surface Cleaning Fluid 4103/1204 1L
1. 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).
2. If any of the components are not suitable for use
then replace the complete fan motor.
3. 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.
4. Make sure that the external body of the fan motor
and the work area is thoroughly cleaned and free
from contamination.
5. 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
Uni-Directional Motor
Refer to Figure 223.
Disassemble
1. Remove the port plugs and drain the oil from the
motor.
2. Mark the gear housing, front housing and rear
housing to make sure of correct alignment when
you assemble the fan motor.
3. Hold the fan motor in a vice on the housing, with
the driveshaft pointing downwards. Use the vice
soft-jaws 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 rear
housing.
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.
10. If necessary, remove the proportional relief valve
cartridge.
11. Clean all of the sealant from the mating surfaces.
Consumable: Surface Cleaning Fluid
12. Discard all the seals and O-rings.

20. 21 - Cooling System
05 - Fan Motor
00 - General
21 - 28 9813/6500-1 21 - 28
Figure 223. Uni-Directional Motor
A
B
V
C
D
E
F
K
W
M
G
J
L
N
E
D P
U
S
R
Q
T
H
H
A Circlip B Seal
C Front housing D Back-up ring
E E-seal F Front bearing block
G O-ring1 H Locating dowels
J Gear housing K O-ring2
L Idler gear M Driveshaft gear
N Rear bearing block P Rear housing
Q Proportional relief valve cartridge R Measuring coupling
S Spring T Ball
U Valve seat V Washer
W Bolt

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22. 21 - Cooling System
05 - Fan Motor
00 - General
21 - 29 9813/6500-1 21 - 29
Inspection
1. Clean and dry all the parts before you do an
inspection.
2. Inspect all O-ring grooves and shaft seal
recesses and make sure that there are no burrs.
3. 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.
4. 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.
5. Inspect the bearing blocks for excessive wear or
scoring on the surfaces that are in contact with
the gears.
6. Inspect the bearing for excessive wear or
damage.
7. 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.
8. Replace the fan motor, if you find any of the
following defects:
8.1. 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
8.2. The PTFE (Polytetrafluoroethylene) coated
bearings in the body or flanges are worn
through so that the bronze base is visible.
8.3. The gear side faces or bearing blocks are
scarred.
8.4. The driveshaft has a wear groove where the
shaft seal lips run.
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.
5. 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.
6. 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.
7. 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.
8. Keep the front housing, with the seal side facing
downwards on a clean flat surface.
9. Apply a thin layer of petroleum jelly to the
exposed face of the front bearing block.
10. 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.
11. 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.
12. Install the idler gear shaft into the remaining
position in the bearing block.
13. Apply a thin layer of clean hydraulic oil to the face
of the driveshaft and idler gears.
14. 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.
15. 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.
16. Apply a layer of petroleum jelly to the seal
grooves in both sides of the gear housing.
17. Apply a thin layer of petroleum jelly on the O-
ring1 and O-ring2 and install them in the gear
housing.
18. 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.
19. Press the housing together with your hands. Do
not force or use any tool.
20. 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.

23. 21 - Cooling System
05 - Fan Motor
00 - General
21 - 30 9813/6500-1 21 - 30
21. 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.
22. 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.
23. Install the bolts (x4) and washers (x4).
24. Hold the fan motor in the vice on the housing, with
the driveshaft pointing downwards. Use a soft-
jaw vice to protect the housing.
25. Tighten the bolts to the correct torque value.
Refer to Table 87.
26. Remove the fan motor from the vice.
27. 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.
28. If removed, install the proportional relief valve
cartridge. Tighten it to the correct torque valve.
Refer to Table 87.
Table 87. Torque Values
Item Description N·m
Q Proportional re-
lief valve car-
tridge
40
W Bolt 56
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.
10. If necessary, remove the proportional relief valve
cartridge.
11. Clean all sealant from the mating surfaces.
Consumable: Surface Cleaning Fluid
12. Discard the seals and O-rings.

24. 21 - Cooling System
05 - Fan Motor
00 - General
21 - 31 9813/6500-1 21 - 31
Figure 224. Bi-Directional Motor
A
B
C
E
D
J
L
N
F
G
K
M
D
P
R
Q
H
H
A Circlip B Shaft seal
C Front housing D Seal
E Front bearing block F O-ring1
G Gear housing H Locating dowels
J O-ring2 K Idler gear
L Driveshaft gear M Rear bearing block
N Solenoid operated control valve P Proportional relief valve cartridge
Q Bolt R Washer