Foreword

The Operator's Manual

You and others can be killed or seriously injured

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

SERVICE MANUAL Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you
do not understand.

Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.

LOADER
422ZX 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
EN - 9813/8400 - ISSUE 3 - 09/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products

Copyright 2018 © JCB SERVICE

78 - After Sales
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
 15 - Engine
09 - Bedplate
00 - General

00 - General Introduction
Introduction .................................................... 15-63 The bedplate acts as the main strength component
Remove and Install ....................................... 15-64 of the engine. it maintains the correct alignment and
supports the weight of the internal components.

Figure 124.
1

1 Bedplate
2 Crankcase

15 - 63 9813/8400-3 15 - 63
 15 - Engine
09 - Bedplate
00 - General

Remove and Install

Special Tools 13. Remove the high duty PTO (Power Take-Off)
Description Part No. Qty. device (if installed).
Template for Sealant 892/12356 1 14. Position the engine upside down in a suitable jig
Bedplate to Crankcase or fixture, supported at the front of the cylinder
(4 Cyl) block.
Torque Wrench 993/70111 1
(10-100Nm) 15. Remove the flywheel, refer to (PIL 15-54).

Consumables 16. Remove the flywheel housing, refer to (PIL

Description Part No. Size 15-54).
Cleaner/Degreaser 4104/1557 0.4 L 17. Remove the fuel injection pump drive gear, refer
- General purpose to (PIL 15-51).
solvent based parts
cleaner 18. Remove the oil pump, refer to (PIL 15-60).

CAUTION This component is heavy. It must only 19. Remove the CCV (Crankcase Ventilation) check
be removed or handled using a suitable lifting valve plug and ball.
method and device.
Figure 125.

Before Removal C
This procedure requires service parts. Make sure D
you have obtained the correct service parts before
you start. Refer to Parts Catalogue.

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. Remove the engine, refer to (PIL 15-00).
3. Remove the drive belt, refer to (PIL 15-18).
4. Remove the crankshaft pulley, refer to (PIL
15-12).
5. Remove the oil sump, refer to (PIL 15-45).
6. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
7. Remove the rocker cover, refer to (PIL 15-42).
8. Remove the fuel injectors, refer to (PIL 18-18).
9. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
10. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
C Check valve plug
11. Remove the fuel injection pump, refer to (PIL D check valve ball
18-18).
20. Remove the high duty PTO idler drive gear (if
12. Remove the starter motor, refer to (PIL 15-75). installed), refer to (PIL 15-51).

15 - 64 9813/8400-3 15 - 64
 15 - Engine
09 - Bedplate
00 - General

21. Remove the crankshaft drive gear, refer to (PIL 23. Remove the rear timing case, refer to (PIL
15-51). 15-51).
22. Remove the camshaft, refer to (PIL 15-15). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).

Figure 126.
4 1 5

11

8 9

7 10

3 P3 2 6

X
12 18
18
18
18
18

13

18

1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)

15 - 65 9813/8400-3 15 - 65
 15 - Engine
09 - Bedplate
00 - General

Remove suitable lifting equipment (if the bedplate is lifted

manually, two people will be required). DO NOT
1. Remove the bedplate peripheral bolts. use a lever to separate the bedplate.
2. Progressively remove the main bearing bolts in 4. Remove and discard the O-ring.
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts. 5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use

Figure 127.
Y P2 Y A (T5) T4

T4

P2

P3

B (T5)
Y Y P2 T6
18
18 18
X
18
T6 18
4 1 5 T6
11

8 9
W

18

12
T6
7 10

3 2 6
13

1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)

15 - 66 9813/8400-3 15 - 66
 15 - Engine
09 - Bedplate
00 - General

T4 Guide pins (x2 obtain locally) T5 Sealant template

T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring

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 15 - Engine
09 - Bedplate
00 - General

Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
Length/Dimension/Distance: 1.5mm
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
removal procedure. Additionally do the following
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.

7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, before removal
the crankcase, NOT the bedplate. The sealant in reverse order. Additionally do the following
template T5 comprises of two pieces, A and B. step.
Modify the template A by removing portion V.
3. Tighten the CCV check valve plug to the correct
Special Tool: Template for Sealant Bedplate to torque value.
Crankcase (4 Cyl) (Qty.: 1)
8. Locate the holes in the templates A and B using
four fixing bolts at positions Y. Use the templates

15 - 68 9813/8400-3 15 - 68
 15 - Engine
09 - Bedplate
00 - General

Table 68. Torque Table

Item Torque Value
1-10 (1st Stage) 50N·m
1-10 (2nd Stage) 115N·m
1-10 (Final Stage) 180°
11 24N·m
C 45–55N·m

15 - 69 9813/8400-3 15 - 69
 15 - Engine
12 - Crankshaft
00 - General

Operation

Lubrication transfer to cross drillings in the crankshaft to feed

each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
diameter of the upper main bearing shell allows oil engine.

Figure 129.

1 Main gallery 2 Drillings (x5)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal

15 - 74 9813/8400-3 15 - 74
 15 - Engine
12 - Crankshaft
00 - General

Check (Condition) Figure 132.

1. Check the main bearing surfaces for damage and

excessive wear.
Figure 130.
C
D
A

C J-jets
D Fixing screws

A Main bearing shells

2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 131.

B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.

15 - 75 9813/8400-3 15 - 75
 15 - Engine
12 - Crankshaft
00 - General

Remove and Install

Consumables reasons (for piston and connecting rod removal

Description Part No. Size for example) remove it now, refer to (PIL 15-06).
Cleaner/Degreaser 4104/1557 0.4 L 12. Remove the fuel injection pump, refer to (PIL
- General purpose 18-18).
solvent based parts
cleaner 13. Remove the starter motor, refer to (PIL 15-75).
CAUTION This component is heavy. It must only 14. Remove the high duty PTO device (if installed).
be removed or handled using a suitable lifting
method and device. 15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
Before Removal
16. Remove the flywheel, refer to (PIL 15-54).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 17. Remove the flywheel housing, refer to (PIL
before you start, refer to Parts Catalogue. 15-54).

2. Make sure that the engine is safe to work on. If 18. Remove the fuel injection pump drive gear, refer
the engine has been running, let it cool before to (PIL 15-51).
you start the service work.
19. Remove the oil pump, refer to (PIL 15-60).
3. Remove the engine, refer to (PIL 15-00).
20. Remove the high duty PTO idler drive gear (if
4. Remove the drive belt, refer to (PIL 15-18). installed), refer to (PIL 15-51).

5. Remove the crankshaft pulley, refer to (PIL 21. Remove the crankshaft drive gear, refer to (PIL
15-12). 15-51).

6. Remove the oil sump, refer to (PIL 15-45). 22. Remove the camshaft, refer to (PIL 15-15).

7. Disconnect and remove the fuel pipes from the 23. Remove the rear timing case, refer to (PIL
injectors, refer to (PIL 18-96). 15-51).

8. Remove the rocker cover, refer to (PIL 15-42). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
9. Remove the fuel injectors, refer to (PIL 18-18). caps, refer to (PIL 15-12).
10. Remove the rocker assembly including the push 25. Remove the bedplate, refer to (PIL 15-09).
rods, refer to (PIL 15-42).
Remove
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however 1. Remove the thrust washers between the
the cylinder head needs to be removed for other crankshaft and crankcase rear main bearing.

15 - 76 9813/8400-3 15 - 76
 15 - Engine
12 - Crankshaft
00 - General

Figure 133.

A
A

A Thrust Washers B Crankshaft

C Rear main bearing

2. Put labels on the thrust washers to make sure Before Installation

that they are installed in the correct positions
during assembly. 1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft 2. Use a suitable degreasing agent to carefully
is lifted manually, two people will be required). clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
4. Carefully lift out the bearing shells. ways or the piston cooling jets.
Figure 134. Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
D
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.

Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
D Main bearing shells then install cooling J jets as follows:

5. It is recommended that the bearing shells are

replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).

15 - 77 9813/8400-3 15 - 77
 15 - Engine
12 - Crankshaft
00 - General

Figure 135. Figure 136.

G
D

E
F

D Main bearing shells

G Bearing location tab
E J jets (x4)
F Fixing screws 4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
3.1. Insert the cooling jets into the crankcase. shells are clean.
3.2. Note: There are different types of cooling Consumable: Cleaner/Degreaser - General
jets installed depending on the engine purpose solvent based parts cleaner
application. The jets are colour coded. 4.2. Assemble the bearing shells into the
3.3. Be sure to install the correct jets. Refer to crankcase bearing saddles. Make sure that
the relevant parts catalogue for the correct the location tab engages into the slot as
cooling jet identification. shown.
3.4. Tighten the retaining screws to the correct 4.3. Important: Make sure that the oil-way holes
torque value. in the bearing saddles align with the holes
in the bearing shell. If the holes are even
4. Install the upper bearing shells as follows: partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:

15 - 78 9813/8400-3 15 - 78
 15 - Engine
12 - Crankshaft
00 - General

Figure 137.

B H

A
A

A Thrust washers B Crankshaft

C Rear main bearing H Oil slot - thrust washers

6.1. Slide the thrust washers between the

crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).

Table 70. Torque Values

Item Nm
F 24

15 - 79 9813/8400-3 15 - 79
 15 - Engine
12 - Crankshaft
03 - Main Bearing

03 - Main Bearing Introduction

Introduction .................................................... 15-80 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-81 bearings on which the crankshaft rotates.
Remove and Install ....................................... 15-81
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.

Figure 138.

A Main bearing
B Crankshaft

15 - 80 9813/8400-3 15 - 80
 15 - Engine
12 - Crankshaft
03 - Main Bearing

Check (Condition) Remove and Install

Refer to: PIL 15-12-00.
1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
Refer to: PIL 15-12-00.
3. Renew any parts that are worn or not within the
specified tolerances.

15 - 81 9813/8400-3 15 - 81
 15 - Engine
12 - Crankshaft
06 - Front Oil Seal

06 - Front Oil Seal

Remove and Install

(For: JCB Tier 2/3 Elec Engine 4 Cyl) Figure 139.

Special Tools C
Description Part No. Qty.
Crankshaft Front Oil 892/01157 1 B
Seal Installation Tool

Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
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. A

3. Get access to the engine.

4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12-12). A Crankshaft oil seal
B Crankcase
C Crankshaft hub
Remove
1. Use a suitable lever behind the lip of the Install
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not 1. Make sure that the counterbore and the
to scratch or damage the counterbore or the crankshaft hub are clean and free from damage
crankshaft hub. Damaged or dirty sealing faces and corrosion. Use a suitable degreasing agent
will cause the oil seal to fail. to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 140.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
140.

15 - 82 9813/8400-3 15 - 82
 15 - Engine
12 - Crankshaft
06 - Front Oil Seal

Figure 140.

F D A

G G
E

A Crankshaft oil seal B Crankcase

C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw

4. Turn the screw to push the seal squarely into Figure 141.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. B
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore A
within the specified tolerance. Refer to Figure
141. G

Dimension: -0.5 -0/+0.5mm

C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.

15 - 83 9813/8400-3 15 - 83
 15 - Engine
12 - Crankshaft
06 - Front Oil Seal

After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).

15 - 84 9813/8400-3 15 - 84
 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

09 - Rear Oil Seal

Remove and Install

(For: JCB Tier 2/3 Elec Engine 4 Cyl) Figure 142. 24mm Hub
Special Tools
Description Part No. Qty.
Crankshaft Rear Oil 892/01156 1 A
Seal Installation Tool
Crankshaft Rear Oil 892/01158 1
Seal Alignment Tool

Note: The flywheel hub and crankshaft rear oil seal

need to be replaced as a pair.

Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If C B
the engine has been running, let it cool before
you start the service work. A Crankshaft rear oil seal
B Flywheel housing
3. Get access to the engine. C Flywheel hub
4. Remove the flywheel, refer to (PIL 15-54). Figure 143. 15mm Hub

Remove
A
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the
counterbore in the flywheel housing. Take care
B
not to scratch or damage the counterbore or the
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.

C E
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
E Fixing bolt

Install (24mm Hub)

1. Make sure that the counterbore and the flywheel
hub are clean and free from damage and
corrosion.

15 - 85 9813/8400-3 15 - 85
 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

Figure 144.

B
D
A
C

A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool

2. To prevent the seal lip rolling over and becoming Special Tool: Crankshaft Rear Oil Seal Alignment
damaged, make sure that you use the oil seal Tool (Qty.: 1)
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over 3. Apply lubricant P80 around the seal outer rubber
the end of the hub, then carefully push the oil seal diameter.
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed 4. Dismantle the oil seal installation tool. Bolt the
the correct way around. centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
Special Tool: Crankshaft Rear Oil Seal the centre body and install the screw.
Installation Tool (Qty.: 1)

Figure 145.
F
B
E
A C H

H
G

G F

A Crankshaft rear oil seal B Flywheel housing

C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw

5. Turn the screw to push the seal squarely into 6. Remove the oil seal installation tool.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. Install (15mm Hub)
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore 1. Make sure that the counterbore and the hub are
within the tolerance specified. clean and free from damage.
Length/Dimension/Distance: 0.5mm

15 - 86 9813/8400-3 15 - 86
 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

Figure 146.

B
D
A
C

A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool

2. Install the new hub on to the crankshaft gear and Special Tool: Crankshaft Rear Oil Seal
install the old hub on the outside of the new hub Installation Tool (Qty.: 1)
to create a double thickness flywheel hub, install Special Tool: Crankshaft Rear Oil Seal Alignment
the fixing bolt as shown at A. Do not touch the Tool (Qty.: 1)
PTFE seal lips of the crankshaft oil seal.
4. Apply the lubricant P80 around the seal outer
3. Make sure that you use the oil seal alignment tool rubber diameter.
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the 5. Dismantle the oil seal installation tool. Use the
alignment tool over the end of the hub, carefully two flywheel bolts to attach the centre body on to
push the oil seal over the alignment tool as far the flywheel hub. Assemble the outer sleeve on
on to the crankshaft hub as possible. Make sure to the centre body include the extension ring and
that the seal is installed the correct way around. install the screw.

Figure 147.
B F
G
A C1 K C2
H
L

K
J

A Crankshaft rear oil seal B Flywheel housing

C1 New hub C2 Old hub
F Flywheel bolts G Oil seal installation tool
H Extension ring J Centre body
K Outer sleeve L Screw

6. Turn the screw to push the seal into position in

the counterbore so that the screw will not turn.

15 - 87 9813/8400-3 15 - 87
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 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal

7. Remove the oil seal installation tool, remove the

old hub and install the fixing bolt. Repeat steps 5
and 6 to fully install the rear oil seal.
8. Remove the oil seal installation tool.

After Installation
1. Install the flywheel, refer to (PIL 15-54).

Table 71. Torque Values

Item Nm
E 47

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 15 - Engine
12 - Crankshaft
12 - Pulley

12 - Pulley 2. The bolts must not be reused. Discard the bolts.

Install
Remove and Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
(For: JCB Tier 2/3 Elec Engine 4 Cyl) steps.
Special Tools 2. Make sure that all items are clean and free from
Description Part No. Qty. damage and corrosion.
Torque Wrench 993/70111 1
(10-100Nm) 3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 4. The bolts are tightened using a torque and
before you start, refer to Parts Catalogue. angle method. Refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before Figure 149.
you start the service work.
3. Get access to the engine.
4. Remove the drive belt. Refer to (PIL 15-18).

Remove
C
1. Remove the fixing bolts and withdraw the pulley
from the crankshaft.
Figure 148.

C Angle gauge (obtain locally)

After Replacement
1. Install the drive belt. Refer to (PIL 15-18).

A Table 72.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·m
2 (Final stage) 180°

A
B
A Crankshaft pulley
B Fixing bolts (x3)

15 - 89 9813/8400-3 15 - 89