Jcb руководство по ремонту кпп

JCB Dump Truck:

JCB HTD5 Tracked Dumpster Service Repair Workshop Manual

JCB TD7 , TD10 Tracked Dumpster Service Repair Workshop Manual

JCB 712 , 716 Articulated Dump Truck Service Repair Manual

JCB 714, 718 Articulated Dump Truck Service Repair Workshop Manual(S/N: 714 From 830000, 718 From 832000)

JCB 714, 718 Articulated Dump Truck Service Repair Workshop Manual(S/N: 714 From 1304500 , 718 From 1304600)

JCB 722 Articulated Dump Truck Service Repair Workshop Manual

JCB 1T-1 High Tip Dumper Service Repair Manual

JCB 1THT Dumper Service Repair Manual

JCB 2TFT, 2THS, 2TST, 3.5TST, 3TFT, 3TST Dumper Service Repair Manual

JCB 6TFT, 6TST Dumper Service Repair Manual

JCB 6T-1 Front Tip, 6T-1 Swivel Tip, 7T-1 Front Tip Hi-Viz, 9T-1 Front Tip Dumper Service Repair Manual

JCB 10TFT, 9TFT, 9TST Dumper Service Repair Manual

JCB Mini/Midi/Micro:

JCB Mini CX Backhoe Loader Service Repair Workshop Manual

JCB 801 Tracked Excavator Service Repair Workshop Manual

JCB 801.4, 801.5, 801.6 Mini Excavator Service Repair Workshop Manual

JCB 802, 802.4, 802 Super Mini Excavator Service Repair Workshop Manual

JCB 802.7, 803, 804 Mini Crawler Excavator Service Repair Workshop Manual

JCB 802.7 plus, 802.7 super, 803 plus, 803 super, 804 plus, 804 super Mini Excavator Service Manual

JCB 805, 8058, 8068, 8078, 808 Tracked Excavator Service Repair Manual

JCB Micro, Micro Plus, 8008, 8010 Excavator Service Repair Manual

JCB 8013, 8015, 8017, 8018, 801 Gravemaster Mini Excavator Service Repair Workshop Manual

JCB 8014 8016 8018 8020 Mini Excavator Service Repair Workshop Manual

JCB 8025Z, 8030Z, 8035Z Mini Excavator Service Repair Workshop Manual

JCB 8025ZTS, 8026CTS, JS30, 8029CTS, 8030ZTS, 8035ZTS Compact Excavator Service Repair Manual

JCB 8026 CTS, JCB 30PLUS Compact Excavator Service Repair Manual

JCB 8027Z, 8032Z Mini Excavator Service Repair Workshop Manual

JCB 8040ZTS, 8045ZTS, 8050ZTS, 8050RTS Mini Crawler Excavator Service Repair Manual

JCB 8040, 8045, 8050, 8055 Mini Crawler Excavator Service Repair Workshop Manual

JCB 8056 Mini Crawler Excavator Service Repair Workshop Manual

Jcb 8061 Mini Crawler Excavator Service Repair Workshop Manual

JCB 8052 8060 Midi Excavator Service Repair Workshop Manual

JCB 8055, 8065 Midi Excavator Service Repair Workshop Manual

JCB 8080 Midi Excavator Service Repair Workshop Manual

JCB 8085 Midi Excavator Service Repair Workshop Manual

JCB 210X , 220X Excavator Service Repair Manual

JCB 15C-1, 16C-1, 18Z-1, 19C-1, 19C-1 PC Compact Excavator Service Repair Manual

JCB 48Z-1, 51R-1 Compact Excavator Service Repair Manual (9813/6200 – 03/2016)

JCB 45Z-1, 48Z-1, 51R-1 COMPACT EXCAVATOR Service Repair Manual (9813/6400  2018)

JCB 55Z-1, 57C-1 MINI EXCAVATOR Service Repair Manual (EN – 9813/6450 – ISSUE 1 – 03/2016)

JCB 55Z-1, 57C-1 Mini Excavator Service Repair Manual (EN – 9813/6250 – ISSUE 1 – 03/2016)

JCB 65R-1 Midi Excavator Service Repair Manual (EN – 9813/4550 – ISSUE 2 – 04/2018)

JCB 67C-1 Mini Excavator Service Repair Manual (S/N: from 1912903 to 1913903 – EN – 9813/3450 – ISSUE 2 – 04/2018)

JCB 100 C-1, 85 Z-1, 86 C-1, 90 Z-1 Mini Excavator Service Repair Manual (EN – 9813/2700 – ISSUE 2 – 2016-09-28)

JCB Skid Steer:

JCB 135 HD, 155 HD Skid Steer Loader Service Repair Manual (S/N: 2431601 and up)

JCB 135, 155, 175, 190, 205, 150T, 190T, 205T Skid Steer Loader (ROBOT) Service Repair Manual (9813/1350)

JCB 135, 155, 175, 190, 205 Skid-Steer Loader Service Repair Manual (EN – 9813/6750 – ISSUE 1 – 04/2016)

JCB 135 [T4F], 150T [T4F], 155 [T4F], 175 [T4F], 190T [T4F], 205T [T4F], 210 [T4F], 215 [T4F] Skid Steer Loader Service Repair Manual

JCB Robot 150, 165, 165HF Skid Steer Loader Service Repair Workshop Manual

JCB 155 , 175 Skid Steer Loader Service Repair Manual (S/N: from 2575651 and up , from 2575701 and up)

JCB Robot 160, 160HF, 170, 170HF, 180, 180HF, 180T, 180THF Skid Steer Loader Service Repair Workshop Manual

JCB Robot 160, 170, 170HF, 180T, 180THF Skid Steer Loader Service Repair Workshop Manual

JCB Robot 185, 185HF, 1105, 1105HF Skid Steer Loader Service Repair Workshop Manual

JCB Robot 190, 190HF, 1110, 1110HF, 190T, 190THF, 1110T, 1110THF Skid Steer Loader Service Repair Workshop Manual

JCB Robot 190 ,1110 Skid Steer Loader Service Repair Workshop Manual

JCB 225, 225T, 260, 260T, 280, 300, 300T, 320T, 330 Skid Steer Loader (ROBOT) Service Repair Workshop Manual (9803/9950-2)

JCB 225T, 250, 250T, 260, 260T, 270, 270T, 280, 300, 300T, 320T, 325T, 330 Skid Steer Loader Service Repair Manual (EN – 9813/7450 – ISSUE 2 – 12/2017)

JCB 225, 225T, 260, 260T, 280, 300, 300T, 320T, 325T, 330 Skid Steer Loader Service Repair Manual (EN – 9813/5150 – ISSUE 2 – 09/2018)

JCB 3TS-8T, 3TS-8W Skid-Steer Loader Service Repair Manual

JCB Teletruk:

JCB 2.0D/G, 2.5D/G, 3.0D/G, 3.0D 4×4, 3.5D 4×4 Teletruk Service Repair Workshop Manual

JCB 2.5D, 2.5G, 3.0D, 3.0G, 3.5D, 3.0D 4×4, 3.5D 4×4, 3.0 D High Lift Teletruk Service Repair Workshop Manual

JCB TLT 25G, TLT 30G TELETRUK (VARIABLE REACH TRUCK) Service Repair Manual

JCB TLT 30D High Lift, TLT 35D, TLT 35D 4×4 TELETRUK (VARIABLE REACH TRUCK) Service Repair Manual

JCB Wheeled Loader:

JCB TM180, TM220 Telescopic Wheeled Loader Service Repair Manual (Publication No. 9803/9995-03)

JCB TM180, TM220 Telescopic Wheeled Loader Service Repair Manual (EN – 9813/3150 – ISSUE 2 – 08/2018)

JCB TM200, TM270, TM300 Farm Master Loader Service Repair Workshop Manual

JCB TM310, TM310S, TM310WM Telescopic Wheeled Loader Service Repair Workshop Manual

JCB TM320, TM420 Telescopic Wheeled Loader Service Repair Manual (EN – 9813/6850 – ISSUE 2 – 04/2018)

JCB TM320 Telescopic Wheeled Loader Service Repair Manual (SN: 2420601 to 2420800 – Publication No. 9813/4700-1)

JCB 427, 435S, 437 Wheel Loader Service Repair Manual (EN – 9813/6100 – ISSUE 4 – 03/2017)

JCB 403 Wheel Loading Shovel Service Repair Workshop Manual (S/N: 1070000 to 1070499)

JCB 403 Wheel Loader Service Repair Manual (S/N: 2394946 and up)

JCB 406, 409 Wheeled Loading Shovel Service Repair Workshop Manual

JCB 406, 407, 408, 409 Wheel Loading Shovel Service Repair Workshop Manual

JCB 419S Wheel Loader Service Repair Manual

JCB 407B ZX, 408B ZX, 409B Z, 410B ZX, 411B ZX Wheeled Loader Service Repair Manual

JCB 410 412 415 420 425 430 Wheeled Loader Service Repair Workshop Manual

JCB 411, 416 Wheeled Loader Service Repair Workshop Manual

JCB 412S, 414S, 416S Wheeled Loader Service Repair Workshop Manual

JCB 411HT, 413S, 417HT Wheeled Loader Service Repair Manual

JCB 418S Wheeled Loading Shovel Service Repair Manual (S/N: 23356 to 2336423)

JCB 422ZX Wheel Loading Shovel Service Repair Manual (2089665 to 2090665) (9813/3800)

JCB 422ZX Wheeled Loader Service Repair Manual (EN – 9813/8400 – ISSUE 3 – 09/2018)

JCB WLS 430ZX PLUS Wheeled Loading Shovel Service Repair Manual (Publication No. 9813/4650-02)

JCB 426 , 436 , 446 Wheeled Loader Service Repair Workshop Manual

JCB 426 , 427 , 435 , 436 , 437 , 446 Wheeled Loading Shovel Service Repair Manual (9803-4160)

JCB 432ZX Wheel Loader Service Repair Manual

JCB 432ZX PLUS Wheeled Loader Service Repair Manual

JCB 434S Wheeled Loader Service Repair Manual (Publication No. 9803/9420-02)

JCB 434S & 435S Wheeled Loading Shovel Service Repair Manual (Publication No. 9803/9420-03)

JCB 435 Wheeled Loader Service Repair Manual (from M/C No. 523778)

JCB 446, 456 Wheeled Loader Service Repair Workshop Manual

JCB 455ZX Wheel Loader Service Repair Manual

JCB 457 Wheeled Loading Shovel Service Repair Manual (S/N from 1907000 onwards – Publication No. 9813-1600-1)

JCB 457 Wheel Loader Service Repair Manual (S/N: from 2244514 onwards – EN – 9813/4150 – ISSUE 6 – 12/2017)

JCB 467 Wheeled Loader Service Repair Workshop Manual

JCB Backhoe Loader:

JCB 1CX, 1CXT Backhoe Loader Service Repair Manual (EN – 9813/6050 – ISSUE 2 – 07/2018)

JCB 2D, 2DS, 3, 3C, 3CS, 3D, 700 Excavator Loader Service Repair Workshop Manual

JCB 1CX, 208S Backhoe Loader Service Repair Workshop Manual

JCB 1CX Series 1 And Series 2 Backhoe Loader Service Repair Workshop Manual

JCB 2CX, 2CXU, 210S, 210SU Backhoe Loader Service Repair Workshop Manual

JCB Midi CX Backhoe Loader Service Repair Workshop Manual

JCB 2CX, 2DX, 210, 212 & VARIANTS Backhoe Loader Service Repair Workshop Manual

JCB 2DX Backhoe Loader Service Repair Manual (S/N: From 1915700 to 1917405 , From 2299800 to 2304689)

JCB 2DXL Backhoe Loader Service Repair Manual

JCB 3CX Backhoe Loader Service Repair Manual (S/N: 2442701 and up)(EN – 9813/7800 ISSUE 1 – 04/2017)

JCB 3CX Backhoe Loader Service Repair Manual (EN – 9813/6650 – ISSUE 3 – 02/2018)

JCB 3CXG Backhoe Loader Service Repair Manual (EN – 9813/4250 – ISSUE 6 – 03/2018)

JCB 3CX 4CX Backhoe Loader Service Repair Workshop Manual(S/N: 2000000 Onwards)

JCB 3CX 4CX Backhoe Loader Service Repair Workshop Manual(S/N: 3CX 290000 to 400000 & 4CX 290000 to 400000)

JCB 3CX , 4CX Backhoe Loader Service Repair Workshop Manual (S/N:3CX 4CX-400001 to 4600000)

JCB 3C, 3CX, 4CX Backhoe Loader Service Repair Workshop Manual (Publication No. 9803/3290-16)

JCB 3CX, 4CX, 214e, 214, 215, 217 & Variants Backhoe Loader Service Repair Workshop Manual

JCB 3CX, 4CX, 214, 215, 217 & Variants Backhoe Loader Service Repair Workshop Manual

JCB 3CX Compact Backhoe Loader Service Repair Manual (EN – 9813/5450 – ISSUE 5 – 11/2017)

JCB 3DX Super, 3DX Xtra, 4DX Backhoe Loader Service Repair Manual (EN – 9823/0000 – ISSUE 1 – 01/2018)

JCB 3DX / 4DX Backhoe Loader Service Repair Manual (Publication No. 9813/2050-5)

JCB 4CX Pilingmaster Backhoe Loader Service Repair Manual

JCB 3CX, 4CX, 5CX Backhoe Loader Service Repair Manual (EN – 9813/6950 – ISSUE 3 – 01/2018)

JCB 3CX, 4CX, 5CX, 5CX Wastemaster Eco Backhoe Loader Service Repair Manual (EN – 9813/6900 – ISSUE 6 – 09/2018)

JCB 4DX Backhoe Loader (India) Service Repair Manual

JCB Tracked Excavator:

JCB AMS JS Machines Service Repair Workshop Manual Supplement

JCB JS70 Tracked Excavator Service Repair Workshop Manual

JCB JZ70 Tracked Excavator Service Repair Workshop Manual

JCB JS81 Tracked Excavator Service Repair Manual

JCB JS85 (JS Auto Range) Tracked Excavator Service Repair Manual

JCB JS 100 Series Tracked Excavators T4i Service Repair Manual (Publication No. 9813/2200-4)

JCB JS110, JS130, JS150LC Tracked Excavator Service Repair Workshop Manual

JCB JS115, JS130, JS130LC, JS145, JS160, JS180 Tracked Excavator Service Repair Manual

JCB JS115, JS130, JS145, JS160, JS180, JS200, JS210, JS220 Tracked Excavator Service Manual

JCB JS115 Auto Tier lll, JS130 Auto Tier lll, JS145 Auto Tier lll Tracked Excavator Service Manual

JCB JS115, JS130, JS145, JS160, JS180, JS190, JS200, JS210, JS220, JS235 (T4 and T2 Engines) Tracked Excavator Service Repair Manual (9813/3200-03)

JCB JS115, JS130, JS131, JS145, JS160, JS180, JS190 EXCAVATOR Service Repair Manual (EN – 9813/7150 – ISSUE 1 – 04/2016)

JCB JS115, JS115 [T2/3], JS130, JS130 [T2/3], JS145 EXCAVATOR Service Repair Manual (EN – 9813/7050 – ISSUE 1 – 04/2018)

JCB JS120 Tracked Excavator Service Repair Manual

JCB JS130, JS160 Tracked Excavator Service Repair Workshop Manual

JCB JZ140 ZTS Tier2 Tracked Excavator Service Repair Workshop Manual

JCB JS140, JS200, JS205, JS215 Tracked Excavator Service Repair Manual (EN – 9813/0400 – ISSUE 7 – 02/2018)

JCB JZ140 Tier3 Tracked Excavator Service Repair Workshop Manual

JCB JZ140 [T4i], JZ141 [T4F] Tracked Excavator Service Repair Manual

JCB JS160 Auto Tier III, JS180 Auto Tier III, JS190 Auto Tier III Tracked Excavator Service Manual

JCB JS200LC, JS240LC, JS300LC, JS450LC Tracked Excavator Service Repair Workshop Manual

JCB JS200 Auto, JS210 Auto, JS220 Auto, JS240 Auto, JS260 Auto Tracked Excavator Service Manual

JCB JS200, JS210, JS220, JS235, JS240, JS260 Auto Tier III Tracked Excavator Service Repair Manual

JCB JS200, JS210, JS220, JS240, JS260 Tracked Excavator Service Repair Workshop Manual (9803/6400)

JCB JS200, JS210, JS220, JS235 Tracked Excavator Service Repair Manual (EN – 9813/7300 – ISSUE 2 – 11/2017)

JCB JS210, JS230 Excavator Service Repair Manual (EN – 9813/8000 – ISSUE 1 – 10/2016)

JCB JS200, JS210, JS220, JS235 EXCAVATOR Service Repair Manual (EN – 9813/7250 – ISSUE 1 – 05/2017)

JCB JZ235 JZ255 Tracked Excavator Service Repair Workshop Manual

JCB JS240, JS260, JS330, JS360 – Tier 4 Tracked Excavator Service Repair Manual (9813/1250-1)

JCB JS290 Auto Tier III Tracked Excavator Service Repair Workshop Manual

JCB JCB305, JS305 Tracked Excavator Service Repair Manual

JCB JS330 Auto Tier2 and Tier3 Tracked Excavator Service Repair Workshop Manual

JCB JS330, JS450, JS460 Tracked Excavator Service Repair Workshop Manual

JCB JS360 Auto Tier III Tracked Excavator Service Repair Workshop Manual

JCB JS300, JS330, JS370 (Tier 4i Isuzu Engine) Tracked Excavators Service Repair Manual (Publication No. 9813/5100-1)

JCB JS300, JS330, JS370 Tracked Excavators Service Repair Manual (EN – 9813/7500 – ISSUE 2 – 10/2017)

JCB JS370 (Tier 2 JCB DieselMax Engine) Tracked Excavator Service Repair Manual(Publication No. 9813/4850-1)

JCB JCB380, JS370 [T2 IND] EXCAVATOR Service Repair Manual (S/N: from 2500652 onwards – EN – 9813/8700 – ISSUE 1 – 10/2017)

JCB JCB140 Excavator Service Repair Manual

JCB Wheeled Excavator:

JCB Hydradig 110W Wheeled Excavator Service Repair Manual

JCB JS130W, JS150W Wheeled Excavator Service Repair Workshop Manual

JCB JS130W, JS145W, JS160W, JS175W Wheeled Excavator Service Repair Workshop Manual

JCB Auto Tier III JS130W , JS145W , JS160W , JS175W Wheeled Excavator Service Manual

JCB JS145W , JS160W , JS20MH Wheeled Excavator Service Repair Manual

JCB JS145W, JS165W Wheeled Excavator Service Repair Workshop Manual

JCB JS175W Auto Wheeled Excavator Service Repair Workshop Manual

JCB JS200W Wheeled Excavator Service Repair Manual (Publication No. 9803/6320 -2)

JCB JS200W Auto Tier III Wheeled Excavator Service Repair Workshop Manual (Publication No. 9803/9540-6)

JCB JS200W Tier 2 and Tier 4i Engines Wheeled Excavators Service Repair Manual(Publication No. 9813/4050-01)

JCB UTV:

JCB Workmax 800D UTV Service Repair Workshop Manual

JCB Groundhog 4×4 Utility Vehicle Service Repair Workshop Manual

JCB Groundhog 6×4 Utility Vehicle Service Repair Workshop Manual

JCB FM25 Ground Care Service Repair Manual (from SN 1069600 to SN 1069999)

JCB FM30 Ground Care Service Repair Manual (from SN 1303000 to SN 1303999)

JCB ZT20D GRASSCUTTER Service Repair Manual

JCB Tractor:

JCB 323HST 327HST Compact Tractor Service Repair Manual

JCB 331HST , 335HST Compact Tractors Service Repair Manual

JCB 354 , 360 Compact Tractor Service Repair Manual

JCB 125 135 145 150 155 185 Fastrac Service Repair Manual

JCB 1115, 1115S, 1125, 1135 FASTRAC Service Repair Manual

JCB 2155 / 2170 Fastrac Service Repair Workshop Manual

JCB 2115 2125 2135 2140 2150 3155 3185 FASTRAC Service Repair Manual

JCB 3000 XTRA Series Fastrac Service Repair Workshop Manual

JCB 3170/Plus , 3190/Plus , 3200/Plus , 3220/Plus , 3230/Plus Fastrac Service Manual

JCB 3200 / 3230 Tier 4 Fastrac Service Repair Workshop Manual

JCB 4160, 4190, 4220 FASTRAC (AGRICULTURAL TRACTOR) Service Repair Manual (SN from 2184000 onwards – EN – 9813/3600 – ISSUE 3 – 07/2018)

JCB 7000 Series Fastrac 7170 7200 7230 Service Repair Workshop Manual

JCB 8250 Fastrac Service Repair Workshop Manual (SN:01138001-01138360)

JCB 8250 Fastrac Service Repair Workshop Manual (SN:01139000-01139999)

JCB 8280, 8310 Fastrac Service Repair Workshop Manual

JCB 8290, 8330 Fastrac (AGRICULTURAL TRACTOR) Service Repair Manual

JCB Forklift:

JCB 504B , 526 Telescopic Handler Service Repair Manual

JCB 505-19, 505-22, 508-40, 506-36, 510-40, 508-40, 505-19, 505-22, 506-36, 508-40, 506B Telescopic Handler (500 Series) Service Repair Manual (From m/c No. 561001)

JCB 525-58, 525-67, 527-58, 527-67, 530-95, 530-110, 530-120, 530-67, 535-67, 537-120, 537-130 Telescopic Handler (500 Series) Service Repair Manual (From m/c No. 561001)

JCB 505-20 Loadall (Rough Terrain Variable Reach Truck) Service Repair Manual

JCB 506C, 506CHL, 508C Loadalls Service Repair Manual (Publication No. 9803/3640U-8)

JCB 506-23, 509-23, 512-26 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (SN: from 2902000 onwards -EN – 9813/9400 – ISSUE 1 – 11/2017)

JCB 506-36 507-42 509-42 510-56 512-56 Telescopic Handler Service Repair Workshop Manual (Publication No. 9803/3740-08)

JCB 506-36, 507-42, 509-42, 510-56, 512-56 Loader (Rough Terrain Variable Reach Truck) Service Repair Manual (S/N From: 1402020 and up)

JCB 506-36, 507-42, 509-42, 510-42, 510-56, 512-56, 514-56, 516-42 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (S/N: from 2433101 onwards – EN – 9813/5050 – ISSUE 2 – 08/2017)

JCB 508-66, 509-45, 510-44, 510-55 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual

JCB 515-40 Telescopic Handler Service Repair Workshop Manual

JCB 516-40 Telescopic Handler Service Repair Manual (S/N: from 2415604 to 2416000)

JCB 520 520M 525 525B 530 530B 540B 540BM Loadall Service Repair Manual

JCB 520-40 524-50 527-55 Compact Telescopic Handler Service Repair Manual

JCB 520-55 526 526S 526-55 Telescopic Handler Service Repair Workshop Manual

JCB 520-50,520 525-50 525-50S Telescopic Handler Service Repair Workshop Manual

JCB 525-60 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (EN – 9813/3900 – ISSUE 3 – 02/2018)

JCB 526 526S 528-70 528S Telescopic Handler Service Repair Workshop Manual

JCB 526-56, 531-70, 535-95, 536-60, 536-70, 541-70, 550-80, 560-80 Loadall (Rough Terrain Variable Reach Truck) Service Repair Manual (EN – 9823/0050 – ISSUE 1 – 06/2017)

JCB 526-56, 531-70, 535-95, 536-60, 536-70, 536-70LP, 541-70, 550-80, 560-80 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (EN – 9813/7600 – ISSUE 3 – 03/2018)

JCB 526-56, 531-70, 531-T70, 533-105, 535-95, 535-T95, 536-60, 536-70, 536-70LC, 536-T70, 536-T70LP, 541-70, 541-T70, 550-80 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (EN – 9813/5600 – ISSUE 4 – 05/2018)

JCB 527-58 Telescopic Handler Service Repair Workshop Manual (9813/0200-2)

JCB 527-58 T4F LOADALL (ROUGH TERRAINVARIABLE REACH TRUCK) Service Repair Manual (S/N From 2330671 and up – EN – 9813/7550 – ISSUE 1 – 04/2018)

JCB 528-70 , 528S Telescopic Handler Loadall Service Repair Manual [528-70 (from S/N 796000) , 528S (from S/N 796102)]

JCB 530 532 533 535 537 540 Telescopic Handler Service Repair Workshop Manual

JCB 531-70 533-105 535-95/125 535-140 536-60 540-140/170 541-70 550-140/170 Loader Service Manual

JCB 531-70, 535-95, 536-60, 536-70, 536-70LP, 541-70, 550-80, 560-80 Service Repair Manual (S/N from 2569936 and up , 2724382 and up)

JCB 531-70/T70,535-95/T95,536-60/T60,541-70/T70,533-105,536-70/T70,526-56 Loader Service Manual

JCB 531-70/T70, 535-95/T95, 536-60/T60/70/T70, 541-70/T70,533-105,526-56, 550-80/T80 Telescopic Handler Service Manual

JCB 531-70, 535-95, 536-60, 541-70, 533-105, 536-70, 526-56, 550-80, 531-T70, 541-T70, 536-T60, 535-T95, 536-T70, 550-T80 Telescopic Handler Service Manual

JCB 531-70, 535-95, 541-70 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (S/N: from 2902000 onwards – EN – 9813/9050 – ISSUE 1 – 01/2018)

JCB 530-110, 530-70 LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual (EN – 9813/8300 – ISSUE 1 – 09/2016)

JCB 532H,537H Telescopic Handler Service Manual(Supplement)

JCB 533-105, 535-v125, 540-140, 540-170, 540-200, 540-v140, 540-v180, 550-140, 550-170 LOADALL Service Repair Manual (EN – 9813/9100 – ISSUE 1 – 11/2017  & EN – 9813/7650 – ISSUE 2 – 04/2018)

JCB 535-v125 Work Platform, 540-170 Work Platform, 540-200 Work Platform, 540-v140 Work Platform, 540-v180 Work Platform LOADALL (ROUGH TERRAIN VARIABLE REACH TRUCK) Service Repair Manual

JCB 540-170, 540-140, 535-125 Hi Viz, 535-140 Hi Viz Telescopic Handler Service Manual

JCB 926 930 940 Forklift Service Repair Manual (9803/5100-16)

JCB 926, 930, 940, 950 Rough Terrain ForkLift Service Repair Manual (9803/5100-19)

JCB 926, 930, 940, 945, 950 ROUGH TERRAIN TRUCK Service Repair Manual (S/N: 2363578 and up) (EN – 9813/6600 – ISSUE 1 – 08/2017)

JCB Load Control Service Manual(Supplement)

JCB 1253 , 1202 , 1553 , 1554 Liftall Service Repair Manual

JCB Roller:

JCB CT160, CT260 Tandem Roller Service Repair Manual

JCB Vibromax 70B Walk Behind Roller Service Repair Workshop Manual

JCB VIBROMAX W1500 Trench Roller Service Repair Manual (UP TO SN JKC42000799)

JCB VIBROMAX W1500 Trench Roller Service Repair Manual(Starting at S/N JKC4200800)

JCB VIBROMAX 253 263 Tandem Roller Service Repair Workshop Manual

JCB VIBROMAX 255 265 Tandem Roller Service Repair Workshop Manual

JCB VIBROMAX 355 365 455 465 Tandem Roller & 355K 365K 455K 465K Combination Roller Service Manual

JCB VIBROMAX 752 Tandem Drum Roller Service Repair Workshop Manual

JCB VIBROMAX 752c Tandem Drum Roller Service Repair Workshop Manual

JCB Vibromax 405 605 606 Single Drum Roller Service Repair Workshop Manual

JCB Vibromax 1103 Single Drum Roller Service Repair Workshop Manual

JCB Vibromax 1105 1106 1405 1805 Single Drum Roller Service Repair Workshop Manual

JCB Vibromax VM46 Single Drum Roller Service Repair Workshop Manual

JCB Vibromax VM66 Single Drum Roller Service Repair Workshop Manual

JCB VIBROMAX VM106 Single Drum Roller Service Repair Manual

JCB VM 115- TIER II Single Drum Roller Service Repair Manual (from SN 2034000 onwards)

JCB VM 115 – TIER III Single Drum Roller Service Repair Manual (from SN 1705097 onwards)

JCB Vibromax VM116 VM146 VM166 VM186 Single Drum Roller Service Manual

JCB VM46D/PD, VM75D/PD, VM115D/PD, VM115H, VM132D/PD, VM146D/PD, VM166D/PD, VM200D/PD Roller Service Repair Manual

JCB VMD70 , VMD100 Double Drum Roller Service Repair Manual

JCB VM117, VM137 Vibratory Roller Service Repair Manual

JCB JCB116, JCB116D, JCB116DD, VM116 ROLLER Service Repair Manual

JCB VMT160 , VMT260 Tier 2 and Tier 4 Roller Service Repair Manual

JCB VMT380, VMT430 Vibratory Tandem Roller Service Repair Manual

JCB VMT860 Tier 3 Vibratory Rollers Service Repair Manual (VMT 860 from SN 1778003 onwards. Publication No. 9813/0750 )

JCB VMT860 Tier 3 Vibratory Rollers Service Repair Manual (VMT860 from SN 2802400 onwards. EN – 9813/7300 – ISSUE 2 – 11/2017)

JCB VMS 55 Single Drum Roller Service Repair Manual (from SN 1401000 to SN 1401999)

JCB VMS 71 , 71-20 , 71-30 Single Drum Roller Service Repair Manual (VMS71 Series)

Mobile Elevating Work Platform:

JCB S1530E, S1930E, S2032E, S2046E, S2632E, S2646E, S3246E, S4046E, S4550E MOBILE ELEVATING WORK PLATFORM Service Repair Manual

Engines:

JCB Dieselmax Tier3 SE Engine (SE Build) Service Repair Workshop Manual

JCB 444 , 448 Dieselmax Mechanical Engine Service Repair Workshop Manual

JCB T4F 444 , T4i 444 , T4i 448 Engine Service Repair Manual

JCB T4F 444 Elec , T4F 448 Elec Engine Service Repair Manual

JCB T4F 3.0 Elec Engine 4 Cyl Service Repair Manual

JCB T2/T3 Mech Engine 4 Cyl Service Repair Manual

JCB T2/T3 Elec Engine 4 Cyl Service Repair Manual

JCB T2 / T3 Elec Engine 6 Cyl. Service Repair Manual

JCB 672 Mechanical Engine Service Repair Manual

Cummins 4B 3.9 / 6B 5.9 Engines Operation and Maintenance Manual

Cummins ISB 5.9 and QSB 5.9 Engines Troubleshooting and Repair Manual

Deutz D2008 / 2009 Engine Service Repair Workshop Manual

Deutz D2009 TD2009 Engine Workshop Service Repair Manual

Deutz 2011 Engines Service Repair Workshop Manual

JCB Isuzu 4HK1 – 6HK1 Engines Service Repair Manual

JCB Isuzu AU-4LE2 , BV-4LE2 Engine Service Repair Manual

JCB Isuzu 6RB1, 6RB1T Diesel Engine Service Repair Manual

JCB Isuzu A1-4JJ1 Engine Service Repair Workshop Manual

Isuzu A-4JG1 Engine Service Repair Manual

JCB Isuzu AA-4BG1T AA-6BG1 BB-4BG1T BB-6BG1T Engine Service Repair Manual

JCB Isuzu AA-6HK1T BB-6HK1T Engine Service Repair Workshop Manual

Isuzu 4HK1 Interim Tier 4 Compatible Engine Service Repair Workshop Manual

Isuzu 6HK1 Interim Tier 4 Compatible Engine Service Repair Workshop Manual

JCB LPG 3.0 Engine Service Repair Manual

JCB JS460 Engine Isuzu AA-6SDIT Service Repair Workshop Manual

JCB Isuzu 4LB1, 4LC1, 4LE1 Engine Workshop Service Repair Manual

Perkins 400 Series Engine (Models 403C-11, 403C-15, 404C-22 and 404C-22T) Service Repair Manual

Perkins 402D 403D 404D Industrial Engines Service Repair Manual (9806-3090)

Lombardini FOCS Series Engine Service Repair Workshop Manual

Lombardini 15LD 225 315 350 400 440 Series Engine Service Repair Manual

Lombardini CHD Series Engine (LDW 1503 – 1603 – 2004 -2004/T – 2204 – 2204/T) Service Repair Manual (9806-4060)

Kohler KDW 1603 – 2204 – 2204/T Engine Service Repair Manual

Kohler KDI 1903TCR – 2504TCR Diesel Engine Service Repair Manual

Scania Industrial Diesel 9 litre engine with 5 cylinders Work description Manual

Scania Industrial and Marine Engines 12 litre Engine Service Repair Workshop Manual

Scania Industrial and Marine Engines 16 litre engine Work Description Manual

Sisu Diesel 33 ,44 ,66 ,74 ,84 ,98 Engine (SISU AGCO 4TH GEN ENGINE) Service Repair Manual

AGCO 5th Generation AWF Engines (types 33, 44, 49, 66, 74, 84 and 98) Service Repair Manual

Sisu Diesel Engine 320, 420, 620, 634 Series Service Repair Workshop Manual

Mahindra Navistar Acteon 6.12 Mechanical Engine Service Repair Workshop Manual

Yanmar TNV Series 2TNV70 , 3TNV70 , 3TNV76 Engine Service Repair Manual

Yanmar Industrial Diesel Engine 3TNV , 4TNV Series Service Repair Manual 

JCB Attachments Service Repair Manual

LOMBARDINI Gearbox (Model No. 51177) Service Repair Manual (9806-4005A)

AGCO OEM Tramsmission (JCB) ML180 T702 Service Repair Manual

JCB SS400 Series Transmission Service Repair Manual

JCB SS500 Series Transmission Service Repair Manual

JCB SS600 Series Transmission Service Repair Manual

JCB SS700 Series Transmission Service Repair Manual

JCB PS700 & PS750 Series Transmission Service Repair Manual

JCB PS760, PS764, PS766 Transmission Service Repair Manual

JCB HS750 Transmission Service Repair Manual

JCB Transmissions Service Repair Manual (9803/8610-18)

JCB SD55 Axles Service Repair Manual

JCB SD70 , SD80 Axles Service Repair Manual

JCB PD70 Axles Service Repair Manual

JCB TG300, TG310 Service Repair Manual

JCB SELF-REGULATING ALTERNATORS Service Repair Manual

JCB CONTROL PANELS Service Repair Manual

www.WorkshopManuals.co.uk

General Information

Care & Safety

Routine Maintenance

Attachments

Body & Framework

Service

Electrics

Manual

3CX, 4CX, 214e, 214, 215,

217 & VARIANTS

Controls

Backhoe

Loader

From M/c No. 930000 Onwards

From M/c No. 903000 Onwards (USA)

Hydraulics

Transmission

Brakes

PUBLISHED BY THE

TECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE; © WORLD PARTS CENTRE,

WATERLOO PARK, UTTOXETER, ST14 5PA

ENGLAND

Tel. ROCESTER (01889) 590312

PRINTED IN ENGLAND

Publication No. 9803/3280 Issue 4

Steering

Engine

1

G

H

K

C

D

E

F

2

3

A

B

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Introduction

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else

SAFETY MUST COME FIRST!

The manual is compiled in sections, the first three are numbered and contain information as follows: machine.

1

2

3

=

=

=

General Information

— includes torque settings and service tools.

Care & Safety

— includes warnings and cautions pertinent to aspects of workshop procedures etc.

Routine Maintenance

— includes service schedules and recommended lubricants for all the

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:

A

B

=

=

Attachments

Body & Framework

…etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.

With the exception of slewing operations ‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.

Machine Nomenclature

In this Service Manual, reference is made to machine models, e.g. 3CX, 4CX, these are European machine model names.

North American machine models have different names, the table below shows the European and the equivalent North

American nomenclature.

European

3CX

4CX

North American

= 214

= 214S, 215S, 217S

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

www.WorkshopManuals.co.uk

Colour Coding

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications.

A390940

Red

Pink

Orange

Blue

Green

Light

Green

Yellow

Full Pressure

Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure.

Pressure

Pressure that is above neutral circuit pressure but lower than that denoted by red.

Servo

Oil pressure used in controlling a device (servo).

Neutral

Neutral circuit pressure.

Exhaust

Cavitation

Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up

Oil trapped within a chamber or line, preventing movement of components (lock up).

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

i

Section 1

www.WorkshopManuals.co.uk

General Information

Section 1

i

Contents Page No.

Machine Identification Plate

Typical Vehicle Identification Number (VIN)

Typical Engine Identification Number

Serial Plates

Torque Settings

Service Tools Numerical List

2 — 1

3 — 1

Service Tools

— Body & Framework

— Electrics

— Hydraulics

4 — 1

4 — 4

4 — 6

— Transmission 4 — 10

— Engine 4 — 1

9

*

Sealing and Retaining Compounds 5 — 1

1 — 1

1 — 1

1 — 1

1 — 2

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section 1

1 — 1

www.WorkshopManuals.co.uk

General Information

Section 1

1 — 1

Machine Identification Plate

Your machine has an identification plate mounted on the loader tower. The serial numbers of the machine and its major units are stamped on the plate.

The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.

The machine and engine serial numbers can help identify exactly the type of equipment you have.

Typical Vehicle

Identification Number (VIN)

SLP 3CX T S V E 930000

A B

C D E F G

A

World Manufacturer Identification

B

Machine Model

C

Steer Type (T= 2WS, F=4WS)

D

Build Type (S=Sideshift, C=Centremount, L=Loader)

E

Year of Manufacture:

2 = 2002

3 = 2003

4 = 2004

5 = 2005

6 = 2006

7 = 2007

8 = 2008

F

Manufacturer Location (E = England)

G

Product Identification Number (PIN)

U.K. and R.O.W.

S218131

Typical Engine

Identification Number

AB 50262 U 500405 P

A B C D E

A

Engine Type

AB = 4 cylinder turbo

B

Build Number

C

Country of Origin

D

Engine Sequence Number

E

Year of Manufacture

A246740

North America

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

1 — 2

www.WorkshopManuals.co.uk

General Information

Section 1

1 — 2

Serial Plates

A

Front Axle (2WS machine)

B

Front Axle (4WS machine)

C

Rear Axle (2WS machine)

D

Rear Axle (4WS machine)

E

Synchro Shuttle Transmission

F

Powershift Transmission

G

Engine

D

S259110

A

S257580

E

F

B

S259100

A401030

9803/3280

C

G

S156571

Purchased from www.WorkshopManuals.co.uk

S260120

Issue 1

Section 1

2 — 1

www.WorkshopManuals.co.uk

General Information

Section 1

2 — 1

Torque Settings

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade ‘S’ Bolts

Bolt Size in (mm)

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

11/4

11/2

(6.3)

(7.9)

(9.5)

(11.1)

(12.7)

(14.3)

(15.9)

(19.0)

(22.2)

(25.4)

(31.7)

(38.1)

Metric Grade 8.8 Bolts

Hexagon (A/F) in

7/16

1/2

9/16

5/8

3/4

13/16

15/16

11/8

15/16

11/2

17/8

21/4

Nm

170

238

407

650

970

14

28

49

78

117

1940

3390

Torque Settings kgf m

1.4

2.8

5.0

8.0

12.0

17.3

24.3

41.5

66.3

99.0

198.0

345.0

lbf ft

125

175

300

480

715

10

20

36

58

87

1430

2500

Bolt Size

M5

M6

M8

M10

M12

M16

M20

M24

M30

M36

(mm)

(5)

(6)

(8)

(10)

(12)

(16)

(20)

(24)

(30)

(36)

Hexagon (A/F) mm

8

10

13

17

19

24

30

36

46

55

Nm

7

12

28

56

98

244

476

822

1633

2854

Torque Settings kgf m

0.7

1.2

3.0

5.7

10

25

48

84

166

291 lbf ft

5

9

21

42

72

180

352

607

1205

2105

Rivet Nut Bolts/Screws

Bolt Size

(mm)

Torque Settings (for steel rivet nuts)

Nm kgf m lbf ft

M3

M4

M5

M6

M8

M10

M12

(3)

(4)

(5)

(6)

(8)

(10)

(12)

1.2

3.0

6.0

10.0

24.0

48.0

82.0

0.12

0.3

0.6

1.0

2.5

4.9

8.4

0.9

2.0

4.5

7.5

18.0

35.5

60.5

Note:

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

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

3 — 1

www.WorkshopManuals.co.uk

General Information

Section 1

3 — 1

Service Tools Numerical List

Page No.

460/15708 Flow Test Adapter

460/15707 Banjo Bolt

1406/0011 Bonded Washer

1406/0014 Bonded Washer

1406/0018 Bonded Washer

1406/0021 Bonded Washer

1406/0029 Bonded Washer

1604/0003 Male Adapter

1604/0004 Male Adapter

1604/0006 Male Adapter

1604/0008 Adapter

1606/0003 Male Adapter

1606/0004 Male Adapter

1606/0007 Male Adapter

1606/0008 Male Adapter

1606/0009 Male Adapter

1606/0012 Male Adapter

1606/0014 Male Adapter

1606/0015 Male Adapter

1606/0017 Male Adapter

1612/0006 Adapter

2401/0222 O-ring

2403/0110 O-ring

2403/0108 O-ring

4101/0651 Retainer (High Strength)

4101/0250 Threadlocker and Sealer (10 ml)

4101/0251 Threadlocker and Sealer (50 ml)

4101/0451 Threadlocker

4102/0502 High Strength Gasketing

4102/0551 High Strength Threadlocker

4102/0933 Clear Silicone Sealant

4102/1212 Multi-Gasket

4102/1951 Threadseal

4102/2309 Black Polyurethane Sealant

4103/2109 Ultra Fast Adhesive (310ml)

4104/0251 Activator (Aersol)

4104/0253 Activator (Bottle)

4104/1203 Active Wipe 205 (250g)

4104/1206 Active Wipe 205 (30 ml)

4104/1310 Hand Cleaner

4104/1538 JCB Cleaner & Degreaser

4104/1557 Cleaner/Degreaser (400 ml)

4201/4906 Black Primer 206J (30ml)

816/00017 Adapter

816/00189 Blanking Cap

816/00190 Blanking Cap

816/00193 Blanking Cap

816/00196 Blanking Cap

816/00197 Blanking Cap

816/00294 Blanking Cap

816/00439 Male Adapter

816/00440 Male Adapter

816/15007 Male Adapter

816/15008 Male Adapter

816/15118 Pressure Test Adapter

816/20008 Adapter

816/20013 Adapter

816/50005 Adapter

816/50043 Adapter

816/55038 Pressure Test ‘T’ Adapter

816/55040 Pressure Test ‘T’ Adapter

816/60096 Adapter

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

4 — 1

4 — 6

4 — 13

4 — 13

4 — 13

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

5 — 1

4 — 13

4 — 13

4 — 7

4 — 7

4 — 7, 13

4 — 6, 4 — 7

4 — 7

4 — 7

4 — 7, 13

4 — 6, 4 — 7

4 — 6

4 — 7

4 — 7

4 — 7

4 — 7

4 — 7

4 — 6, 4 — 7

4 — 7

4 — 6, 4 — 7

4 — 7

4 — 7

4 — 7

4 — 7

4 — 7

4 — 6

4 — 6

4 — 6

4 — 8

4 — 8

4 — 6

4 — 6

4 — 8

5 — 1

5 — 1

5 — 1

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

Page No.

*

823/10420 Shim Kit — Powershift gearbox, layshaft clutch

825/00410 Crowfoot Wrench

825/99833 Adapter for 825/00410

826/01099 Rivet Nut

826/01101 Rivet Nut

826/01102 Rivet Nut

826/01103 Rivet Nut

826/01104 Rivet Nut

826/01105 Rivet Nut

892/00011 Spool Clamp

892/00041 De-glazing Tool

892/00047 Adapter

892/00048 Adapter

892/00049 Adapter

892/00051 Adapter

892/00055 Blanking Plug

892/00056 Blanking Plug

892/00057 Blanking Plug

892/00058 Blanking Plug

892/00059 Blanking Plug

892/00060 Blanking Plug

892/00071 Male Adapter

892/00074 Female Connector

892/00075 Female Connector

4 — 8

4 — 8

4 — 7

4 — 8

4 — 8

892/00076 Female Connector

892/00077 Female Connector

4 — 8

4 — 8

892/00078 Connector 4 — 6

892/00137 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 — 7

892/00167 Ram Seal Protection Sleeve 90 mm 4 — 9

892/00174 Measuring Cup

892/00179 Bearing Press

892/00180 Seal Fitting Tool

892/00181 Replacement Plastic Boss

892/00182 Bearing Pad Driver

892/00223 Hand Pump

892/00224 Impulse Extractor

892/00225 Adapter for Extractor

892/00253 Pressure Test Kit

892/00255 Pressure Test Adapter

4 — 11

4 — 10

4 — 9

4 — 9

4 — 12

4 — 7

4 — 11

4 — 11

4 — 6

4 — 6

4 — 8

4 — 19

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 17

4 — 4

4 — 4

4 — 1

4 — 1

4 — 1

4 — 1

4 — 1

4 — 1

892/00256 Pressure Test Adapter

892/00257 Pressure Test Adapter

892/00258 Pressure Test Adapter

892/00259 Pressure Test Adapter

892/00260 Pressure Test Adapter

892/00261 Pressure Test Adapter

892/00262 Pressure Test ‘T’ Adapter

892/00263 Pressure Test ‘T’ Adapter

892/00264 Pressure Test ‘T’ Adapter

892/00265 Pressure Test ‘T’ Adapter

892/00268 Flow Monitoring Unit

892/00269 Sensor Head

892/00270 Load Valve

892/00271 Adapter

892/00272 Adapter

892/00273 Sensor Head

892/00274 Adapter

892/00275 Adapter

892/00276 Adapter

892/00277 Adapter

892/00278 Gauge

892/00279 Gauge

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6, 4 — 7

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 6

4 — 7

4 — 6

4 — 6

4 — 6

4 — 7

4 — 7

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section 1

3 — 2

www.WorkshopManuals.co.uk

General Information

Section 1

3 — 2

Service Tools Numerical List

Page No.

*

*

892/00282 Shunt

892/00283 Tool Kit Case

892/00284 Tachometer

892/00285 Hydraulic Oil Temperature Probe

892/00286 Surface Temperature Probe

892/00293 Connector Pipe

892/00294 Connector Pipe

892/00298 Fluke Meter

892/00301 Flow Test Adapter

892/00302 Flow Test Adapter

892/00309

892/00333

892/00334

892/00335

892/00706

ARV Test Kit

Heavy Duty Socket

Ram Seal Fitting Tool

ARV Cartridge Removal Tool

Test Probe

892/00812 Drive Coupling Spanner

892/00817 Heavy Duty Socket

892/00818 Heavy Duty Socket

892/00819 Heavy Duty Socket

892/00822 Splined Bolt Socket

4 — 7

4 — 11

4 — 9

4 — 7

4 — 6, 4 — 7

4 — 10

4 — 11

4 — 11

4 — 11

4 — 11

4 — 4

4 — 4

4 — 4

4 — 4

4 — 4

4 — 6

4 — 6

4 — 4

4 — 10

4 — 10

892/00836 Lifting Wire Assembly

892/00842 Glass Lifter

892/00843 Folding Stand

892/00844 Long Knife

892/00845 Cartridge Gun

892/00846 Glass Extractor (Handles)

892/00847 Nylon Spatula

892/00848 Wire Starter

892/00849 Braided Cutting Wire

892/00881 Spool Seal Fitting Tool

892/00882 Alternator Pulley Socket

892/00891 Wheel Hub Seal — Fitting Tool

892/00918 Setting Tool Kit

892/00920 Flow Test Adapter

892/00922 12.2” T/C Alignment Tool

892/00948 Charging Kit

892/00949 Pressure Gauge

892/00956 Timing Pin

892/00964 Test Point (1/8BSP)

892/00965 Test Point (3/8BSP)

4 — 5

4 — 10

4 — 16

4 — 10

4 — 10

4 — 9

4 — 9

4 — 19

4 — 12

4 — 12

4 — 19

4 — 2

4 — 1

4 — 3

4 — 1

4 — 2

4 — 3

4 — 2

4 — 3

4 — 7

*

*

892/00966 Test Point (1/4BSP

892/01016 Ram Seal Protection Sleeve 25 mm

892/01017 Ram Seal Protection Sleeve 30 mm

892/01018 Ram Seal Protection Sleeve 40 mm

892/01019 Ram Seal Protection Sleeve 50 mm

892/01020 Ram Seal Protection Sleeve 50 mm

(slew ram)

892/01021 Ram Seal Protection Sleeve 60 mm

892/01022 Ram Seal Protection Sleeve 60 mm

(slew ram)

892/01023 Ram Seal Protection Sleeve 65 mm

892/01024 Ram Seal Protection Sleeve 70 mm

892/01025 Ram Seal Protection Sleeve 75 mm

892/01026 Ram Seal Protection Sleeve 80 mm

892/01027 Piston Seal Assembly Tool

892/01033 Electronic Service Tool Kit

892/01096 Speed Sensor Test Harness

892/01079 Ring Socket Spanner

Mainshaft setting ring

892/01080 Ring Socket Spanner

Layshaft setting ring

892/01077 Synchro Shuttle Gearbox Selector

4 — 12

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 9

4 — 18

4 — 17

4 — 13

4 — 13

9803/3280

Shaft Lock Screw

892/01078 Synchro Shuttle Gearbox

Mainshaft Adjuster

Page No.

4 — 13

4 — 13

892/01076 Synchro Shuttle Support Plate

Transfer gear end float setting

892/01082 Powershift — Assembly Cradle

892/01083 Powershift — Assembly tool, transfer gear

892/01084 Powershift — Transfer gear, bearing assembly

892/01085 Powershift — Seal fitting tool

926/15500 Rubber Spacer Blocks

992/04000 Torque Multiplier

992/04800 Flange Spanner

992/07608 Bearing Adapter

992/07609 Bearing Adapter

992/07610 Bearing Adapter

992/07611 Bearing Adapter

992/07612 Bearing Adapter

992/07613 Bearing Adapter

992/09100 Spool Clamp

992/09200 Charging Tool

992/09300 Ram Spanner

992/09400 Ram Spanner

992/09500 Ram Spanner

992/09600 Ram Spanner

992/09700 Ram Spanner

992/09900 Ram Spanner

992/10000 Ram Spanner

992/12300 12V Mobile Oven

992/12400 Static Oven — 2 Cartridge

992/12600 Static Oven — 6 Cartridge

992/12800 Cut-Out Knife

992/12801 «L» Blades

993/55700 Direct Glazing Kit

993/59500 Impulse Extractor Adapter

993/68100 Slide Hammer Kit

993/69800 Seal Kit

993/70111 Breakback Torque Wrench

993/85700 Battery Tester

7210/0001 Dummy Plug

7210/0002 Wire Seal (1.4 — 2.2 mm dia.)

7210/0003 Wire Seal (2.2 — 2.9 mm dia.)

7212/0001 2 Way Socket Connector

7212/0002 2 Way Pin Housing

7212/0003 2 Way Socket Retainer

7212/0004 2 Way Pin Retainer

7213/0001 3 Way Socket Connector

7213/0002 3 Way Pin Housing

7213/0003 3 Way Socket Retainer

7213/0004 3 Way Pin Retainer

7213/0005 3 Way Socket Connector (DT)

7213/0006 3 Way Pin Housing (DT)

7213/0007 3 Way Socket Retainer (DT)

7213/0008 3 Way Pin Retainer (DT)

7214/0001 4 Way Socket Connector

7214/0002 4 Way Pin Housing

7214/0003 4 Way Socket Retainer

7214/0004 4 Way Pin Retainer

7216/0001 6 Way Socket Connector

4 — 13

4 — 17

4 — 17

4 — 15

4 — 4

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 8

4 — 1

4 — 2

4 — 2

4 — 2

4 — 2

5 — 1

4 — 11

4 — 3

4 — 6

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 10

4 — 10

4 — 8

4 — 1

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 8

4 — 17

4 — 17

4 — 3

4 — 12

4 — 12

4 — 10

4 — 10

4 — 10

4 — 10

Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section 1

3 — 3

www.WorkshopManuals.co.uk

General Information

Section 1

3 — 3

Service Tools Numerical List

*

*

*

*

*

7216/0002 6 Way Pin Housing

7216/0003 6 Way Socket Retainer

7216/0004 6 Way Pin Retainer

7218/0001 8 Way Socket Connector

7218/0002 8 Way Pin Housing

7218/0003 8 Way Socket Retainer

7218/0004 8 Way Pin Retainer

7219/0001 10 Way Socket Connector

7219/0002 10 Way Pin Housing

7219/0003 10 Way Socket Retainer

7219/0004 10 Way Pin Retainer

7219/0005 14 Way Socket Connector

7219/0006 14 Way Pin Housing

7219/0007 14 Way Socket Retainer

7219/0008 14 Way Pin Retainer

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

4 — 5

The following parts are replacement items for kits and would normally be included in the kit numbers quoted on pages

1/3-1 and 1/3-2.

Service Tools Numerical List

Replacement item for kit no. 892/00180

892/00181

Replacement items for kit no. 892/00253

892/00201 Replacement Gauge

892/00202 Replacement Gauge

892/00203 Replacement Gauge

892/00254 Replacement Hose

Page No.

4 — 9

4 — 6

4 — 6

4 — 6

4 — 6

Replacement items for kit no. 892/00309

892/00340 Test Block Body

892/00341 Setting Body

892/00343 Spanner

892/00345 Anti-Cavitation Lock Out Bung

993/68300 Adjusting Pin

4 — 7

4 — 7

4 — 7

4 — 7

4 — 7

Replacement items for kit no. 993/68100

993/68101 Slide Hammer

993/68102 End Stops

993/68103 Adaptor — M20 x 5/8″ UNF

993/68104 Adaptor — M20 x 1″ UNF

993/68105 Adaptor — M20 x M20

993/68106 Adaptor — M20 x M24

993/68107 Bar — M20 x M20 X 800MM

993/68108 Adaptor — M20 x 7/8″ UNF

993/68109 Adaptor — M20 x M12

4 — 3

4 — 3

993/68110 Adaptor — M20 x 5/8″ UNF (Shoulder) 4 — 3

993/68111 Adaptor — M20 x 1/2″ UNF 4 — 3

4 — 3

4 — 3

4 — 3

4 — 3

4 — 3

4 — 3

4 — 3

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section 1

4 — 1

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 1

Service Tools

(cont’d)

Section B — Body & Framework

826/01099

826/01101

826/01103

826/01102

826/01104

826/01105

M6 x 16mm Rivet Nut

M6 x 19mm Rivet Nut

M8 x 18mm Rivet Nut

M8 x 21mm Rivet Nut

M10 x 23mm Rivet Nut

M10 x 26mm Rivet Nut

Installation Tool Available from:

Bollhoff Fastenings Ltd.

Midacre

The Willenhall Estate

Rose Hill

Willenhall

West Midlands, WV13 2JW

S261210

Hand Cleaner

— special blend for the removal of polyurethane adhesives.

JCB part number — 4104/1310

(454g; 1 lb tub)

S186240

Cartridge Gun

— hand operated — essential for the application of sealants, polyurethane materials etc.

JCB part number — 892/00845

S186270

12V Mobile Oven

— 1 cartridge capacity — required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket

(715/04300).

JCB part number — 992/12300

S186250

9803/3280

Purchased from www.WorkshopManuals.co.uk

Folding Stand for

Holding Glass

essential for preparing new glass prior to installation.

JCB part number —

892/00843

S186280

Issue 1

Section 1

4 — 2

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 2

Service Tools (cont’d)

Section B — Body & Framework

240V Static Oven

— available with 2 or 6 cartridge capacity — required to pre-heat adhesive prior to use.

No plug supplied. Note: 110V models available upon request — contact JCB Technical Service.

JCB part number:

992/12400 — 2 Cartridge x 240V

992/12600 — 6 Cartridge x 240V

Glass Lifter

— minimum 2 off — essential for glass installation, 2 required to handle large panes of glass.

Ensure suction cups are protected from damage during storage.

JCB part number — 892/00842

S186300

S186260

Wire Starter

— used to access braided cutting wire

(below) through original polyurethane seal.

JCB part number — 892/00848

Cut- Out Knife

— used to remove broken glass.

JCB part number — 992/12800

S186310

S186340

‘L’ Blades

— 25 mm (1 in) cut — replacement blades for cut-out knife (above).

JCB part number — 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles)

— used with braided cutting wire (below) to cut out broken glass.

JCB part number — 892/00846

S186320

9803/3280

Purchased from www.WorkshopManuals.co.uk

S186350

Issue 1

Section 1

4 — 3

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 3

Service Tools (cont’d)

Section B — Body & Framework

Braided Cutting Wire

— consumable heavy duty cut-out wire used with the glass extraction tool (above).

JCB part number — 892/00849

(approx 25 m length)

Long Knife

— used to give extended reach for normally inaccessible areas.

JCB part number — 892/00844

S186330

S186360

Rubber Spacer Blocks

— used to provide the correct set clearance between glass edge and cab frame.

JCB part number — 926/15500

(unit quantity = 500 off)

Nylon Spatula

general tool used for smoothing sealants — also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

JCB part number — 892/00847

S186470 S186550

Slide Hammer Kit — 993/68100

1 :993/68101 Slide Hammer

2 :993/68102 End Stops

3 :993/68103 Adaptor — M20 x 5/8″ UNF

4 :993/68104 Adaptor — M20 x 1″ UNF

5 :993/68105 Adaptor — M20 x M20

11

6 :993/68106 Adaptor — M20 x M24

7 :993/68107 Bar — M20 x M20 X 800MM

8 :993/68108 Adaptor — M20 x 7/8″ UNF

9 :993/68109 Adaptor — M20 x M12

10 :993/68110 Adaptor — M20 x 5/8″ UNF (Shoulder)

11 :993/68111 Adaptor — M20 x 1/2″ UNF

2

2

5

2

1

6

4

9

8

7

3

10

9803/3280

S196910

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 4

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 4

Service Tools (cont’d)

Section C — Electrics

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter 85

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital Tachometer

5 892/00282 100 amp Shunt — open type

6 892/00285 Hydraulic Temperature Probe

S188231

993/85700 Battery Tester 892/00882 Socket for Alternator Pulley Nut

825/00410

825/99833

15 mm Crowfoot Wrench

Adapter

S239510 S216770

9803/3280

S216200

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

4 — 5

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 5

Service Tools (cont’d)

Section C — Electrics

1

2A :7212/0002

2B :7212/0004

2C :7212/0003

2D :7212/0001

3A :7213/0002

3B :7213/0004

3C :7213/0003

3D :7213/0001

4A :7213/0006

4B :7213/0008

4C :7213/0007

4D :7213/0005

5A :7214/0002

5B :7214/0004

5C :7214/0003

5D :7214/0001

Electrical Repair Kit

2 Way Pin Housing

2 Way Pin Retainer

2 Way Socket Retainer

2 Way Socket Connector

3 Way Pin Housing

3 Way Pin Retainer

3 Way Socket Retainer

3 Way Socket Connector

3 Way Pin Housing (DT)

3 Way Pin Retainer (DT)

3 Way Socket Retainer (DT)

3 Way Socket Connector (DT)

4 Way Pin Housing

4 Way Pin Retainer

4 Way Socket Retainer

4 Way Socket Connector

6A :7216/0002

6B :7216/0004

6C :7216/0003

6D :7216/0001

7A :7218/0002

7B :7218/0004

7C :7218/0003

7D :7218/0001

8A :7219/0002

8B :7219/0004

8C :7219/0003

8D :7219/0001

9A :7219/0006

9B :7219/0008

9C :7219/0007

9D :7219/0005

10 :7210/0001

11 :7210/0002

12 :7210/0003

6 Way Pin Housing

6 Way Pin Retainer

6 Way Socket Retainer

6 Way Socket Connector

8 Way Pin Housing

8 Way Pin Retainer

8 Way Socket Retainer

8 Way Socket Connector

10 Way Pin Housing

10 Way Pin Retainer

10 Way Socket Retainer

10 Way Socket Connector

14 Way Pin Housing

14 Way Pin Retainer

14 Way Socket Retainer

14 Way Socket Connector

Dummy Plug

Wire Seal (1.4 — 2.2 mm dia.)

Wire Seal (2.2 — 2.9 mm dia.)

1

9803/3280

Purchased from www.WorkshopManuals.co.uk

S188380

Issue 1

Section 1

4 — 6

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 6

Service Tools (cont’d)

Section E — Hydraulics

S267300

Hydraulic Circuit Pressure Test Kit

892/00253

:892/00201

:892/00202

:892/00203

:892/00254

993/69800

892/00706

Pressure Test Kit

Replacement Gauge 0-20 bar (0-300 lbf/in

2

)

Replacement Gauge 0-40 bar (0-600 lbf/in

2

)

Replacement Gauge 0-400 bar (0-6000 lbf/in

2

)

Replacement Hose

Seal Kit for 892/00254 (can also be used with probe 892/00706)

Test Probe

S188121

S188131

Pressure Test ‘T’ Adapters

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point

816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point

816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point

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

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

892/00265 1 in M BSP x 1 in F BSP x Test Point

Pressure Test Adapters

892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point

892/00257 1/2 in BSP x Test Point

892/00258 5/8 in BSP x Test Point

816/15118 3/4 in BSP x Test Point

892/00259 1 in BSP x Test Point

892/00260 1.1/4 in BSP x Test Point

892/00261 5/8 in UNF x Test Point

S200141

Flow Test Equipment

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 — 100 l/min (0 — 22 UK gal/min)

892/00293 Connector Pipe

892/00270 Load Valve

1406/0021 Bonded Washer

1604/0006 Adapter 3/4 in M x 3/4 in M BSP

1612/0006 Adapter 3/4 in F x 3/4 in M BSP

892/00271 Adapter 3/4 in F x 5/8 in M BSP

892/00272 Adapter 5/8 in F x 3/4 in M BSP

816/20008 Adapter 3/4 in F x 1/2 in M BSP

892/00275 Adapter 1/2 in F x 3/4 in M BSP

892/00276 Adapter 3/4 in F x 3/8 in M BSP

892/00277 Adapter 3/8 in F x 3/4 in M BSP

892/00273 Sensor Head 0 — 380 l/min

892/00294 Connector Pipe

1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078 Connector 1 in F x 1 in F BSP

1604/0008 Adapter 1 in M x 1 in M BSP

1606/0012 Adapter 1 in M x 3/4 in M BSP

816/20013 Adapter 3/4 in F x 1 in M BSP

9803/3280

Purchased from www.WorkshopManuals.co.uk

S188151

Issue 1

Section 1

4 — 7

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 7

Service Tools (cont’d)

Section E — Hydraulics

892/00881 Valve Spool

Seal Fitting Tool

Components for Valve Block A.R.V. Testing

For 4CX Variable Flow machines use 25/201103

892/00309

1 : 892/00340

2 : 892/00341

3 : 993/68300

4 : 892/00343

5 : 892/00345

6 892/00335

A.R.V. Pressure Test Kit

Test Block Body

Setting Body

Adjusting Pin

Spanner

Anti-cavitation Lock Out Bung

A.R.V. Cartridge Removal Tool

4

6

2

S261220

1

Hand Pump Equipment

892/00223 Hand Pump

892/00137 Micro-bore Hose 1/4 in BSP x 3 metres

892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point

892/00706 Test Probe

892/00278 Gauge 0 — 40 bar (0 — 600 lbf/in 2 )

892/00279 Gauge 0 — 400 bar (0 — 6000 lbf/in 2 )

S193850

Bonded Washers

1406/0011

1406/0018

1406/0014

1406/0021

1406/0029

1/4 in. BSP

1/2 in. BSP

5/8 in. BSP

3/4 in. BSP

1.1/4 in. BSP

5

3

S196700

S188140

Male Adapters — BSP x NPT (USA only)

816/00439 3/8 in. x 1/4 in.

816/00440 1/2 in. x 1/4 in.

816/15007 3/8 in. x 3/8 in.

816/15008 1/2 in. x 3/8 in.

Male Adapters — BSP x BSP

1606/0003 3/8 in. x 1/4 in.

1604/0003 3/8 in. x 3/8 in.

892/00071 3/8 in. x 3/8 in. taper

1606/0004 1/2 in. x 1/4 in.

1606/0007 1/2 in. x 3/8 in.

1604/0004 1/2 in. x 1/2 in.

1606/0017 5/8 in. x 1/2 in.

1606/0008 3/4 in. x 3/8 in.

1606/0009 3/4 in. x 1/2 in.

1604/0006 3/4 in. x 3/4 in.

1606/0012 3/4 in. x 1 in.

1606/0014 3/4 in. x 1.1/4 in.

1606/0015 1 in. x 1.1/4 in.

S193860

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 8

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 8

Service Tools (cont’d)

Section E — Hydraulics

Female Cone Blanking Plug

892/00055 1/4 in. BSP

892/00056 3/8 in. BSP

892/00057 1/2 in. BSP

892/00058 5/8 in. BSP

892/00059 3/4 in. BSP

892/00060 1 in. BSP

Male Cone Blanking Cap

816/00294 1/4 in. BSP

816/00189 3/8 in. BSP

816/00190 1/2 in. BSP

816/00197 5/8 in. BSP

816/00196 3/4 in. BSP

816/00193 1 in. BSP

S193880

S193870

892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051 1 in. BSP (A) x 1/4 in. BSP (B)

816/50005 1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096 3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017 1 in. BSP (A) x 1 in. BSP (B)

992/09100 Excavator Spool Clamp

892/00011 Spool Clamp

S193890

Female Connectors

892/00074 3/8 in. BSP x 3/8 in. BSP

892/00075 1/2 in. BSP x 1/2 in. BSP

892/00076 5/8 in. BSP x 5/8 in. BSP

892/00077 3/4 in. BSP x 3/4 in. BSP

S193900

Hexagon Spanners for Ram Pistons and End Caps

992/09300 55mm A/F

992/09400 65mm A/F

992/09500 75mm A/F

992/09600 85mm A/F

992/09700 95mm A/F

992/09900 115mm A/F

992/10000 125mm A/F

9803/3280

S216210

Purchased from www.WorkshopManuals.co.uk

S193930

Issue 1

Section 1

4 — 9

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 9

Service Tools (cont’d)

Section E — Hydraulics

S216230

20mm

7mm

11o

10mm

5mm

892/00180 Seal Fitting Tool for fitting ‘O’ ring and kin ring to Hydraulic Steer Unit

892/00181 Replacement Plastic Boss

110mm

175mm

R

3m m

R 1.4mm

3o

892/01027 Piston Seal Assembly Tool

338500

S216250

892/00334 Ram Seal Fitting Tool

892/00948 Charging Kit (without gauge)

892/00949 Gauge

S308271

9803/3280

S338410

Ram Seal Protection Sleeves

892/01016 For 25 mm Rod Diameter

892/01017 For 30 mm Rod Diameter

892/01018 For 40 mm Rod Diameter

892/01019 For 50 mm Rod Diameter

892/01020 For 50 mm Rod Diameter (slew ram)

892/01021 For 60 mm Rod Diameter

892/01022 For 60 mm Rod Diameter (slew ram)

892/01023 For 65 mm Rod Diameter

892/01024 For 70 mm Rod Diameter

892/01025 For 75 mm Rod Diameter

892/01026 For 80 mm Rod Diameter

892/00167 For 90 mm Rod Diameter

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 10

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 10

Service Tools (cont’d)

Section F — Transmission

892/00812 Drive Coupling Spanner for front axle and gearbox yoke couplings

A

892/00920 Flow Test Adapter

B

892/00301 Flow Test Adapter

C

892/00302 Flow Test Adapter

892/00179 Bearing Press (use with appropriate adapters)

S196720

A

S266880

B

892/00922 12.2” Torque Converter Alignment Tool

C

S267260

S188200

992/07608 Bearing Adapter

992/07609 Bearing Adapter

992/07610 Bearing Adapter

992/07611 Bearing Adapter

992/07612 Bearing Adapter

992/07613 Bearing Adapter

S188160

892/00891

Fitting Tool Assembly for

Wheel Hub Seals

S227760

S261230

Torque Measuring Tool for Wheel Hub Seals

Manufacture locally, procedures in this manual show checking the wheel hub seal using a rolling force.

However, the torque can be measured using above locally manufactured tool.

Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft) excluding seal drag. Maximum permissible including seal drag is 40 Nm (29.5 lbf ft).

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 11

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 11

Service Tools (cont’d)

Section F — Transmission

892/00224

Impulse Extractor Set for Hub Bearing Seals

S216290

892/00817 17 mm A/F x 3/4in. square drive

892/00818 22 mm A/F x 3/4in. square drive

892/00819 15 mm A/F x 1/2in. square drive

892/00333 19 mm A/F x 3/4in. square drive

S197070

892/00225

993/59500

Adapter — Impulse Extractor

Small 17mm to 25mm

Medium 25mm to 45mm

Large 45mm to 80mm

Adapter — Impulse Extractor (syncro shuttle and powershift transmission)

892/00174

Measuring Cup — Pinion Head Bearing

S190770

892/00822

Splined Bolt Socket for driveshafts

S197060

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

4 — 12

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 12

Service Tools (cont’d)

Section F — Transmission

992/04800

Flange Spanner — for locking pinion flange while pinion nut is slackened or torque set

S216310

892/00182 Bearing Pad Driver

S197040

992/04000

Torque Multiplier (use in conjunction with a torque wrench to give a

5:1 multiplication when tightening pinion nuts)

S197030

9803/3280

S316250

Test Point

1 892/00964 Test point (1/8 BSP) Powershift

2 892/00965 Test point (3/8 BSP) Powershift

3 892/00966 Test point (1/4 BSP) Syncro Shuttle

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 13

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 13

Service Tools

(cont’d)

Section F — Transmission

892/01077 Synchro Shuttle Gearbox — Selector

Shaft Lock Screw

892/01078 Synchro Shuttle Gearbox — Mainshaft

Adjuster

A395350

Powershift Gearbox Flow Test Adaptor

1

460/15708 Flow Test Adapter

2

460/15707 Banjo Bolt

3

2401/0222 O-ring

4

2403/0110 O-ring

5

2403/0108 O-ring

6

1604/0004 Adapter

7

1406/0018 Sealing Washer

2

A396510

Synchro Shuttle Gearbox — Setting ring socket spanners

892/01079

(Mainshaft setting ring)

A396590

892/01080

(Layshaft setting ring)

5

4

1

7

A396600

6

3

A313250

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

4 — 14

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 14

Service Tools (cont’d)

Section F — Transmission

S267300

Hydraulic Circuit Pressure Test Kit (also used for main hydraulic system tests)

892/00253

:892/00201

:892/00202

:892/00203

:892/00254

993/69800

892/00706

Pressure Test Kit

Replacement Gauge 0-20 bar (0-300 lbf/in

2

Replacement Gauge 0-40 bar (0-600 lbf/in

2

Replacement Hose

Seal Kit for 892/00254 (can also be used with probe 892/00706)

Test Probe

)

)

Replacement Gauge 0-400 bar (0-6000 lbf/in

2

)

S188121

Flow Test Equipment (also used for main hydraulic system tests)

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 — 100 l/min (0 — 22 UK gal/min)

892/00293 Connector Pipe

892/00270 Load Valve

1406/0021 Bonded Washer

1604/0006 Adapter 3/4 in M x 3/4 in M BSP

1612/0006 Adapter 3/4 in F x 3/4 in M BSP

892/00271 Adapter 3/4 in F x 5/8 in M BSP

892/00272 Adapter 5/8 in F x 3/4 in M BSP

816/20008 Adapter 3/4 in F x 1/2 in M BSP

892/00275 Adapter 1/2 in F x 3/4 in M BSP

892/00276 Adapter 3/4 in F x 3/8 in M BSP

892/00277 Adapter 3/8 in F x 3/4 in M BSP

892/00273 Sensor Head 0 — 380 l/min

892/00294 Connector Pipe

1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078 Connector 1 in F x 1 in F BSP

1604/0008 Adapter 1 in M x 1 in M BSP

1606/0012 Adapter 1 in M x 3/4 in M BSP

816/20013 Adapter 3/4 in F x 1 in M BSP

S188151

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

4 — 15

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 15

Service Tools (cont’d)

Section F — Transmission

1

5

9803/3280

A396960

6

6

A396930

7

3

A396950

4

A396580

Purchased from www.WorkshopManuals.co.uk

A396940

8, 9

Issue 1

Section 1

4 — 16

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 16

Service Tools (cont’d)

Section F — Transmission

Solid Spacer Setting Kit

Synchro Shuttle Gearbox, SD70, SD80

Axles

1

892/00918

2

921/52627

3

993/70111

4

892/01076

5

6

7

892/01075

997/11000

998/10567

Setting Tool Kit

Spacer 14.20 Service use

Breakback Torque Wrench

Support Bracket —

Synchro Shuttle Gearbox

Support Bracket

PD70, SD80 Rear Axles

Support Bracket

SD55, SD70 Front Axles

SD80 Pinion Shaft Adaptor

8

921/53300

Comprises of:

921/53322

921/53323

921/53324

921/53325

921/53301

921/53302

921/53303

921/53304

921/53305

921/53306

921/53307

921/53308

921/53309

921/53310

921/53311

921/53312

921/53313

921/53314

921/53315

921/53316

921/53317

921/53318

921/53319

921/53320

921/53321

Spacer Kit — SD55 Axles

Spacer thickness mm

13.550

13.575

13.600

13.625

13.650

13.675

13.700

13.725

13.750

13.775

13.800

13.825

13.850

13.875

13.900

13.925

13.950

13.975

14.000

14.025

14.050

14.075

14.100

14.125

14.150

9

921/53400 Spacer Kit — Sychro Shuttle Gearbox,

SD70, SD80 Axles

Comprises of:

921/52606

829/30413

921/52607

829/30414

921/52608

829/30415

921/52609

829/30416

921/52610

829/30417

921/52611

921/53424

921/53425

921/53426

921/53427

921/53428

921/52628

829/30405

921/52629

829/30406

921/52630

829/30407

921/52601

829/30408

921/52602

829/30409

921/52603

829/30410

921/52604

829/30411

921/52605

829/30412

921/53401

921/53402

921/53403

921/53404

921/53405

921/53406

921/53407

921/53408

921/53409

921/53410

921/53411

921/53412

921/53413

921/53414

921/53415

921/53416

921/53417

921/53418

921/53419

921/53420

921/53421

921/53422

921/53423

921/52626

Note:

After using a spacer, obtain a replacement to keep the set complete.

Spacer thickness mm

13.000

13.025

13.050

13.075

13.100

13.125

13.150

13.175

13.200

13.225

13.250

13.275

13.300

13.325

13.350

13.375

12.600

12.625

12.650

12.675

12.700

12.725

12.750

12.775

12.800

12.825

12.850

12.875

12.900

12.925

12.950

12.975

13.400

13.425

13.450

13.475

13.500

13.525

13.550

13.575

13.600

13.625

13.650

13.675

13.700

13.725

13.750

13.775

13.800

13.825

13.850

13.875

13.900

13.925

13.950

14.000

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 17

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 17

Service Tools (cont’d)

Section F — Transmission

892/01083 Powershift — Assembly tool, transfer gear.

892/01084 Powershift — Transfer gear, bearing assembly.

*

892/01085 Powershift — Seal fitting tool

When removing the Powershift gearbox use of a special transmission jack is strongly recommended. This jack can also be used when removing Synchro Shuttle gearboxes.

Note that the jack must be used with special support plates, see below.

A402680

*

Powershift — Support plates, for use with transmission jack,

Manufacture locally, for details see

Section F, Service

Tools.

892/01082 — Powershift — Assembly Cradle, for details see

Section F, Service Tools.

* Powershift — Gearbox hydraulic pump removal tools, allow pump to be removed with torque converter housing fitted to gearbox. Manufacture locally, for details see

Section F,

Service Tools.

*

823/10420 Thrust Washer Kit — Powershift gearbox — Layshaft clutch

*

892/01096

Comprises of:

823/10421

823/10422

823/10423

823/10424

823/10425

823/10426

Washer thickness mm

4.3

4.4

4.5

4.6

4.7

4.8

Speed Sensor Test Harness —

Powershift Gearbox

298910

9803/3280 Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section 1

4 — 18

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 18

Service Tools (cont’d)

Section F — Transmission

*

Powershift Gearbox — 6 Speed (ShiftMaster)

Electronic Service Tool Kit

892/01033 Kit comprises:

1

Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable ShiftMaster diagnostics software.

1

2

Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types.

3

Interconnecting cable, DLA to machine ECU diagnostics socket.

4

Kit carrying case.

2

3

B

J

H

C

A

G

D

E

F

4

A406130

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section 1

4 — 19

www.WorkshopManuals.co.uk

General Information

Section 1

4 — 19

Service Tools (cont’d)

Section K — Engine

892/00836

Lifting Wire Assembly (for engine removal)

S219080

S192390

892/00041 De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)

892/00936 Timing pin for fuel injection pump

(AK, AM, AR)

A314530

892/0104 Adaptor for compression testing

(AK, AM, AR)

For details of other engine service tools refer to Engine

Service Manual, Publication No. 9806/0100 or 9806/2140 for low emission engines.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

5 — 1

www.WorkshopManuals.co.uk

General Information

Section 1

5 — 1

Sealing and Retaining Compounds

JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

JCB Threadlocker and Sealer

Threadseal

Threadlocker

Activator

Cleaner / Degreaser

Direct Glazing Kit

† Ultra Fast Adhesive

† Active Wipe 205

† Black Primer 206J

Clear Silicone Sealant

Black Polyurethane Sealant

JCB Cleaner & Degreaser

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter.

A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/1212 50ml

A locking fluid for use on threads larger than

50mm dia.

A cleaning primer which speeds the curing rate of anaerobic products.

4102/0551 50ml

For all retaining parts which are unlikely to be dismantled. 4101/0651 50ml

A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to

50mm diameter, and for hydraulic fittings up to 25mm diameter.

4101/0250 10ml

4101/0251 50ml

A medium strength thread sealing compound.

4102/1951 50ml

4101/0451 50ml

4104/0251 (1ltr)

4104/0253 Bottle (200ml)

For degreasing components prior to use of anaerobic adhesives and sealants.

For one pane of glass, comprises items marked † below plus applicator nozzle etc.

For direct glazing

For direct glazing

For direct glazing

To seal butt jointed glass

4104/1557 400ml

993/55700

4103/2109 310 ml

4104/1206 30 ml

4104/1203 250 g

4201/4906

4102/0933

30 ml

To finish exposed edges of laminated glass 4102/2309 310 ml

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1538 Aerosol

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

i

Section 2

www.WorkshopManuals.co.uk

Care & Safety

Section 2 i

Contents

Safety Notices

General Safety

Operating Safety

Maintenance Safety

Page No.

1 — 1

2 — 1

3 — 1

4 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 2

1 — 1

www.WorkshopManuals.co.uk

Care & Safety

Section 2

1 — 1

Safety Notices

In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

!

DANGER

Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

!

WARNING

Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

!

CAUTION

Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 2

2 — 1

www.WorkshopManuals.co.uk

Care & Safety

Section 2

2 — 1

All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.

Do not work with the machine until you are sure that you can control it.

Do not start any job until you are sure that you and those around you will be safe.

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.

Remember

BE CAREFUL

BE ALERT

BE SAFE

GEN-1-6

General Safety

!

WARNING

Decals

You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine.

Make sure replacement parts include warning decals where necessary.

INT-1-3-4

!

WARNING

Lifting Equipment

You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

INT-1-3-7

!

WARNING

Care and Alertness

All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-5

!

WARNING

Raised Attachments

Raised attachments can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked.

INT-1-3-8

!

WARNING

Clothing

You can be injured if you do not wear the proper clothing.

Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

INT-1-3-6

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 2

3 — 1

www.WorkshopManuals.co.uk

Care & Safety

Section 2

3 — 1

Operating Safety

!

WARNING

Machine Condition

A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine.

INT-2-1-2

!

WARNING

Controls

You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.

INT-2-1-3

!

WARNING

Machine Limits

Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.

INT-2-1-4

!

WARNING

Engine/Steering Failure

If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

INT-2-1-5

!

WARNING

Engine

The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

INT-2-1-6/1

!

WARNING

Entering/Leaving

Always face the machine when entering and leaving the cab.

Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails.

INT-2-1-7

!

WARNING

Exhaust Gases

Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air.

INT-2-1-10

!

WARNING

ROPS/FOPS Structure

The machine is fitted with a Roll Over Protection Structure

(ROPS) and a Falling Objects Protection Structure (FOPS).

You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the

ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.

INT-2-1-9/3

!

WARNING

Communications

Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

!

WARNING

Ramps and Trailers

Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.

INT-2-2-6

!

DANGER

Sparks

Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

INT-2-2-10

!

WARNING

Powershift Transmission

Do not change from a high gear to a low gear (for instance,

4th to 1st) in one sudden movement whilst the machine is moving. Otherwise the machine will rapidly decelerate, you or others could be killed or seriously injured. When selecting lower gears, allow the engine speed to drop before each gear change.

2-1-1-9/1

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 2

4 — 1

www.WorkshopManuals.co.uk

Care & Safety

Section 2

4 — 1

Maintenance Safety

!

WARNING

Repairs

Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

GEN-1-5

!

WARNING

Modifications and Welding

Non-approved modifications can cause injury and damage.

Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB distributor for advice before modifying the machine.

INT-3-1-2/1

!

WARNING

Metal Splinters

You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses.

INT-3-1-3

!

WARNING

Electrical Circuits

Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-1-4

!

WARNING

Communications

Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing. Before starting the engine make sure the others are clear of the danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.

INT-3-1-5

!

WARNING

Petrol

Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.

INT-3-1-6

!

WARNING

Battery

A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged.

INT-3-1-7

!

WARNING

Battery Gases

Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery.

Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

INT-3-1-8

!

WARNING

Battery Terminals

The machine is negatively earthed. Always connect the negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.

When disconnecting the battery, disconnect the earth (-) lead first.

INT-3-1-9

!

WARNING

Hydraulic Fluid

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.

INT-3-1-10/1

!

DANGER

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

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 2

4 — 2

www.WorkshopManuals.co.uk

Care & Safety

Section 2

4 — 2

Maintenance Safety (cont’d)

!

WARNING

Diesel Fuel

Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.

INT-3-2-2

!

WARNING

Oil

Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

!

WARNING

Soft Ground

A machine can sink into soft ground. Never work under a machine on soft ground.

INT-3-2-4

!

WARNING

Tyres and Rims

Over-inflated or over-heated tyres can explode. Follow the instructions in this handbook for inflating the tyres. Do not weld or cut rims. Get a tyre/wheel specialist to do any repair work.

INT-3-2-6

!

WARNING

Hot Coolant

The cooling system is pressurised when the engine is hot.

Hot coolant can spray out when you remove the radiator cap. Let the system cool before removing the radiator cap.

To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap.

INT-3-2-9

!

WARNING

Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidently flying out.

GEN 6-2

!

CAUTION

Rams

The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion.

INT-3-2-10

!

CAUTION

Cleaning

Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-11

!

CAUTION

‘O’ rings, Seals and Gaskets

Badly fitted, damaged or rotted ‘O’ rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use

Triochloroethane or paint thinners near ‘O’ rings and seals.

INT-3-2-12

!

WARNING

Fires

If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator’s cab until you need to use it.

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an elecrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible.

Firefighters should use self-contained breathing apparatus.

INT-3-2-7/1

!

WARNING

Jacking

A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks.

Always support a jacked-up machine on axle stands before working underneath it.

INT-3-2-8

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 2

4 — 3

www.WorkshopManuals.co.uk

Care & Safety

Section 2

4 — 3

Maintenance Safety (cont’d)

!

WARNING

Hydraulic Hoses

Damaged hoses can cause fatal accidents. Inspect the hoses regularly for:

Damaged end fittings

Chafed outer covers

Ballooned outer covers

Kinked or crushed hoses

Embedded armouring in outer covers

Displaced end fittings.

INT-3-3-2

!

WARNING

Safety Strut

Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

2-1-1-6

!

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.

GEN-1-1

!

WARNING

Waxoyl contains turpentine substitute, which is flammable.

Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

Do not weld near the affected area during the drying period.

Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

5-3-1-9

!

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

!

WARNING

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.

HYD 1-3

!

WARNING

JCB Extradig Dipper Lubricant

JCB Extradig dipper lubricant contains 1.53% lead. The repeated swallowing of very small quantities can cause chronic lead poisoning. Do not smoke or touch food while handling this lubricant. Dispose of waste (rags etc.) in accordance with local regulations.

2-1-1-8

!

WARNING

Fluoroelastomeric Materials

Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton,

Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY

BURN.

New fluoroelastomeric components at ambient temperature require no special safety precautions.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO

NOT TOUCH COMPONENT OR SURROUNDING AREA.

Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

1 Ensure that components have cooled then remove and place material into plastic bags.

2 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

3 Thoroughly wash contaminated area with detergent and water.

4 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately.

INT-3-3-5/1

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

i

Section 3

www.WorkshopManuals.co.uk

Routine Maintenance

Section 3 i

Contents

Lubricants — Health and Safety

Hygiene

Storage

Handling

First Aid — Oil

Spillage

Fires

Service Schedules

Loader Arm Safety Strut

Installing and Removing

Checking for Damage

Cleaning the Machine

Engine Panels

Opening and Closing the Bonnet

Removing and Fitting a Side Panel

Seat Belt

Checking the Seat Belt Condition and Security

Greasing

General

Loader Arms

Backhoe Quickhitch

Front Axle (2 Wheel Drive Machines)

Front Axle (4 Wheel Drive Machines)

Front Axle (All Wheel Steer Machines)

Rear Axle (All Wheel Steer Machines)

Extending Dipper

Driveshafts

6 — in — 1 Clamshovel

Stabilisers (Centremount Machines)

Loader Quickhitch

Power Sideshift

Kingpost

Knuckle (if fitted)

Backhoe Quickhitch (Hydraulic)

Tyres and Wheels

Tyre Inflation

Checking the Wheel Nut Torques

B

rakes

Parking Brake Adjustment

Checking the Foot Brake Fluid Level

Engine Air Filter

Changing the Elements

Page No.

7 — 1

7 — 1

8 — 1

10 — 1

10 — 1

11 — 1

11 — 1

12 — 1

9 — 5

9 — 6

9 — 6

9 — 6

9 — 7

9 — 7

9 — 8

9 — 8

9 — 1

9 — 1

9 — 2

9 — 3

9 — 3

9 — 4

9 — 4

9 — 5

2 — 1

2 — 1

2 — 1

2 — 1

2 — 1

2 — 1

3 — 1

4 — 1

5 — 1

6 — 1

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

ii

Section 3

www.WorkshopManuals.co.uk

Routine Maintenance

Section 3

ii

Contents

Engine Oil and Filter

Checking the Oil Level

Changing the Oil and Filter

*

Engine Cooling System

Checking the Coolant

Changing the Coolant

Adjusting the Fan Belt

Cleaning the Cab Heater Filter

Fuel System

Types of Fuel

Fuel Standards

Low Temperature Fuels

Fatty Acid Methyl Ester Fuels

Petrol

Advice

Filling the Tank

Draining the Filter

Changing the Filter Element

Draining the Sediment Bowl

Bleed the System

Synchro Shuttle Gearbox

Checking the Oil Level

Changing the Oil and Filter

Powershift Gearbox

Checking the Oil Level

Changing the Oil Filter

Hydraulic System

Checking the Fluid Level

Hydraulic Tank Cap

Changing the Filter Element

Changing the Suction Strainer

Front and Rear Axle (All Wheel Steer Machines)

Checking the Differential Oil Level

Changing the Differential Oil

Checking the Hub Oil Levels

Changing the Hub Oil

Front and Rear Axle (Two Wheel Steer Machines)

Checking the Oil Level

Changing the Oil

Battery

Warning Symbols

First Aid — Electrolyte

Checking the Electrolyte Level

Battery Isolator

Page No.

13 — 1

13 — 1

14 — 1

14 — 1

14 — 2

14 — 2

*

*

15 — 1

15 — 1

15 — 1

15 — 1

15 — 1

15 — 1

15 — 2

15 — 2

15 — 2

15 — 3

15 — 3

16 — 1

16 — 1

17 — 1

17 — 2

*

18 — 1

18 — 1

18 — 2

18 — 3

19 — 1

19 — 1

19 — 2

19 — 2

19 — 3

19 — 3

21 — 1

21 — 2

21 — 2

21 — 3

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section 3 iii

www.WorkshopManuals.co.uk

Routine Maintenance

Section 3 iii

Contents

Hydraulic Oil Cooler

Cleaning the Tubes/Fins

Stabiliser Legs

Wear Pads

Wear Pad Adjustment

Air Conditioning

Adjusting the Compressor Drive Belt

Hose Burst Protection Valve (if fitted)

Checking Hose Burst Protection Valve

Lowering a Load

Service Capacities and Lubricants

Coolant Mixtures

Page No.

23 — 1

25 — 1

25 — 1

26 — 1

27 — 1

27 — 1

28 — 1

28 — 2

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

2 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Lubricants — Health and Safety

Section 3

2 — 1

It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.

Hygiene

JCB lubricants are not a health risk when used properly for their intended purposes.

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.

Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Storage

Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

Waste Disposal

All waste products should be disposed of in accordance with all the relevant regulations.

The collection and disposal of used oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

Handling

New Oil.

There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Used Oil.

Used engine crankcase lubricants contain harmful contaminants.

Here are precautions to protect your health when handling used engine oil:

1

Avoid prolonged, excessive or repeated skin contact with used oil.

2

Apply a barrier cream to the skin before handling used oil.

3

Note the following when removing engine oil from skin:

a

Wash your skin thoroughly with soap and water.

b

Using a nail brush will help.

c

Use special hand cleansers to help clean dirty hands.

d

Never use petrol, diesel fuel, or paraffin for washing.

4

Avoid skin contact with oil soaked clothing.

5

Don’t keep oily rags in pockets.

6

Wash dirty clothing before re-use.

7

Throw away oil-soaked shoes.

First Aid — Oil

Eyes.

In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

Swallowing.

If oil is swallowed do not induce vomiting. Get medical advice.

Skin.

In the case of excessive skin contact, wash with soap and water.

Spillage

Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Fires

Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self-contained breathing apparatus.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 3

3 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Service Schedules

Section 3

3 — 1

A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.

!

WARNING

Maintenance

M aintenance must be done by suitably qualified personnel. Before attempting any maintenance work, make sure the machine is safe. Park on level ground. If it is necessary to work with the loader arms raised, then the loader arm safety strut must be fitted as shown in

Loader Arm Safety Strut in MAINTENANCE section.

2-3-1-1

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

Calendar equivalents:

10 Hours = Daily

50 Hours = Weekly

500 Hours = Six Months

1000 Hours = Yearly

2000 Hours = 2 Years

Pre-start Cold Checks

Service Points and Fluid Levels

ENGINE

Oil level

Oil and Filter

∀

Air Cleaner Outer Element #

Air Cleaner Inner Element

Fuel Filter

Fuel Filter

Coolant Quality/Level

Operation 10 50 †100 500 1000 2000

Hr Hr Hr Hr Hr Hr

— Check

!

— Change

— Change

— Change

— Change

— Drain

— Check

!

Fuel Sedimenter — Drain and Clean

Fan Belt Tension/Condition — Check

Valve Clearances and Clean Breather Gauze (if fitted)

∃

— Check and Adjust

Engine Mounting Bolts for Tightness ∃ — Check

Radiator — Clean

All Hoses — Condition — Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

TRANSMISSION, AXLES

AND STEERING

Transmission Oil Level

Transmission Oil

%

Transmission Filter

Axle Oil Level (incl. Hubs when applicable)

&

Axle Oil (incl. Hubs when applicable)

∋

Axle Oil — Limited Slip Differential

Tyre Pressures/Condition

Front Hub Bearings

∃

Transmission Strainer

Drive Shafts

Steer Axle Movement/Shimming ∃

Steer Axle Pivots and Linkages

(

Front Axle Main Pivot

HYDRAULICS

Oil Level

)

Oil

∃

Oil Filter

Rams — Chrome Condition

— Check

!

— Change

— Change

— Check

— Change

— Change

— Check

!

— Check

— Clean

— Security/Grease

— Check

— Grease

— Grease

!

— Check

!

— Sample/Change

— Change

— Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 3

3 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Service Schedules

Section 3

3 — 2

Pre-start Cold Checks

Service Points and Fluid Levels

Hydraulic Oil Cooler

Hydraulic Oil Strainer

Hydraulic Tank Filler Cap (with integral filter)

Hydraulic Pump Drive Shaft

BRAKES

Brake System Fluid Level

Brake System Fluid ∃

Parking Brake

ELECTRICS

Battery Electrolyte Level (if applicable)

Wiring for Chaffing/Routing

Battery Terminals for Condition and Tightness

BODYWORK AND CAB

All Pins and Bushes

Door/Window Hinges

All Cables

Cab Heater Filter #

Extending Dipper

Hydraclamp

∃

Door — Fit and Catches

Cab Seat — Operation

Front Mudguards — Security (if fitted)

Windscreen Washer Fluid Level

Boom Lock Engagement

Condition of Paintwork

Stabiliser Legs (Sideshift)

Machine Generally

∃

Power Sideshift Wear Pads

Power Sideshift Wear Pads

Power Sideshift Chain

Power Sideshift Chain Tension

ATTACHMENTS

6-in-1 Clam Shovel

Backhoe & Loader Quick Hitch

Functional Test and Final Inspection

ENGINE

Idle Speed ∃

Stall Speed ∃

Maximum No-Load Speed

∃

Exhaust Smoke (excessive)

Exhaust System Security ∃

Air Inlet System Security

Throttle System and Control Cable

∃

TRANSMISSION, AXLES AND STEERING

Steer Modes — Operation/Phasing

2WD/4WD Selection

Wheel Nuts Torque

Forward/Reverse and Gear Change — Operation

Operation 10 50 †100 500 1000 2000

Hr Hr Hr Hr Hr Hr

— Clean

— Clean

— Change

— Examine/Grease

!

!

!

!

!

!

!

!

!

— Check

!

— Change

— Check and Adjust

— Check

— Check

— Check

— Check and Grease

!

— Lubricate

— Lubricate

— Clean/Change

— Adjust/Grease

— Check and Adjust

— Check

— Check

— Check

— Check

!

— Check

!

— Check

— Check/Adjust

— Check and Clean

!

— Grease

!

— Check

— Lubricate

— Check/Adjust

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

— Grease

!

— Grease

!

!

!

!

!

!

!

!

!

!

!

Operation 10 50 †100 500 1000 2000

Hr Hr Hr Hr Hr Hr

— Check and Adjust

— Check

— Check and Adjust

— Check

— Check

— Check

— Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

— Check

!

— Check

— Check

!

— Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 3

3 — 3

www.WorkshopManuals.co.uk

Routine Maintenance

Service Schedules

Section 3

3 — 3

Functional Test and Final Inspection

Hydraulic Speed Control — Operation (if fitted)

Steer Circuit Pressure ∃

Transmission Main Line Pressure ∃

Transmission Dump Operation

Neutral Start Operation

Clutch Pack Pressures ∃

HYDRAULICS

MRV Pressure

∃

Operation All Services

Hose Burst Protection Valves (if fitted)

Offloader Valve Pressure

∃

Auxiliary Circuit & Pressures

∃

BRAKES

Foot Brake — Operation

Parking Brake — Operation

Servo Operation (if fitted)

Operation 10 50 †100 500 1000 2000

Hr Hr Hr Hr Hr Hr

— Check

— Check

— Check

— Check

— Check

— Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

— Check and Adjust

— Check

— Check

— Check and Adjust

— Check and Adjust

— Check

!

— Check

!

— Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

ELECTRICS

Starter Motor

Alternator — Output

All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc)

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

— Check

— Check

— Check

!

— Check

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

!

BODYWORK AND CAB

Teeth and Side Cutters

Doors and Windows — Fitment/Leaks

Seat/Seat Belts

— Check

— Check

— Check

!

!

!

!

!

!

!

!

!

!

!

!

† Note:

First 100 Hours Service only, to be completed by your JCB Distributor.

&

Note:

Check for leaks every 50 hours, check level if leaking.

)

Note:

Check the hydraulic fluid level with the loader and backhoe in the travel position.

∃

Note:

Jobs which should only be done by a specialist are indicated by a

†

.

∀

Note:

If operating under arduous conditions, change the engine oil and filter every 250 hours.

∗

Note:

Check generally for leaks on ALL systems, for example, hydraulic, engine (coolant, fuel and oil), transmission, brakes, axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with the recommended fluid after repair. Examples of machine general damage are paintwork, toe plate, glazing rubbers etc., repair any damage as required. If any of the repair or top up procedures are not detailed in this handbook, then contact your local JCB Distributor for advice.

#

Note:

If operating in dusty working environments, change more frequently.

(

Note:

The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice.

%

Note:

After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (eg. water contamination).

∋

Note:

After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

4 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Loader Arm Safety Strut

Section 3

4 — 1

Installing

Install the loader arm safety strut as detailed below before working underneath raised loader arms.

!

WARNING

Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

2-1-1-6

1 Empty the Shovel and Raise the Loader Arms fully.

2 Stop the Engine

Remove the starter key.

!

WARNING

You could be killed or injured if the loader control is accidentally operated. Make sure no-one comes near the machine while you release the safety strut.

2-3-1-2

3 Release the Strut a

Release fastener

A

.

b

Remove strut

C

from its stowage bracket.

4 Install the Strut a

Push strut

C

over the ram piston rod.

b

Secure the strut in position with strap

B

.

5 Lower the Strut Onto the Cylinder

To prevent any chance of the loader arms creeping down and trapping your fingers, the loader arms should be carefully lowered onto the safety strut as shown.

Start the engine and slowly lower the loader arms onto the safety strut, stop the movement immediately the weight of the loader arms is supported by the safety strut.

Note:

When lowering the loader, operate the control lever carefully. ‘Feather’ the lever to lower the loader very slowly.

Removing

1 Fully Raise the Loader Arms

To take the weight off the safety strut.

A

C

2 Stop the Engine

Remove the starter key.

!

WARNING

You could be killed or injured if the loader control is accidentally operated. Make sure no one comes near the machine while you remove the safety strut.

2-3-1-3

3 Remove the Strut a

Undo the strap

B

.

b

Remove the strut

C

from the ram piston rod.

4 Stow the Strut

Secure the strut in its stowage position with fastener

A

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S215110

B

C

S161710

Issue 1

Section 3

5 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Checking for Damage

Section 3

5 — 1

Inspect steelwork for damage. Note damaged paintwork for future repair.

Make sure all pivot pins are correctly in place and secured by their locking devices.

Ensure that the steps and handrails are undamaged and secure.

Check for broken or cracked window glass. Replace damaged items.

Check all bucket teeth for damage and security.

Check all lamp lenses for damage.

Inspect the tyres for damage and penetration by sharp objects.

Check that all safety decals are in place and undamaged. Fit new decals where necessary.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

6 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Cleaning the Machine

Section 3

6 — 1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground and stop the engine.

Clean the machine using water and/or steam. Do not allow mud, debris etc to build upon the machine, pay particular attention to the following areas:

1 Backhoe hoses passing through mainframe.

2 Around twin slew rams.

3 Twin ram slew recess in chassis (centremount).

4 Kingpost slide rails (sideshift).

5 Kingpost hose tray and bottom ‘shelf’ (sideshift).

6 Recess between slew ram and kingpost casting

(sideshift).

Stabiliser cavities can become clogged when operating in soft/wet ground conditions. Remove and clean away all debris that may have built up.

Do not allow mud to build up on the engine and transmission. Make sure the radiator grille is not clogged up.

!

WARNING

Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Please inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris.

5-3-1-12/2

Avoid using neat detergent — always dilute detergents as per the manufacturer’s recommendations, otherwise damage to the paint finish may occur.

It is important to note that excessive power washing can cause damage to the seals or bearings. Take care during routine machine washing not to direct high power water jets directly at oil seals or universal joints.

Note:

The machine must always be greased after pressure washing or steam cleaning.

Always adhere to local regulations regarding the disposal of debris created from machine cleaning.

The illustrations show some of the areas that must be thoroughly cleaned as required.

S272900

S272880

S272890

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 3

7 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Engine Panels

Section 3

7 — 1

Opening and Closing the Bonnet

To release the bonnet, pull handle

A

, the bonnet will automatically open and be supported on gas struts.

To close the bonnet, push the bonnet down, make sure it is locked in place and the side panels are located correctly.

A

Removing and Fitting a Side Panel

!

WARNING

The loader arms must be raised and locked before you remove an engine side panel. Keep the arms locked up until the side panel is put back. If you do not lock the loader arms, the shovel can fall and you could be crushed. See Loader Arm Safety Strut in MAINTENANCE section.

2-3-1-4/1

!

WARNING

Do not remove the engine side panel while the engine is running.

2-3-1-5

1

Raise the loader arms and fit the safety strut, see

Loader Arms Safety Strut

.

2

Stop the engine, and remove the starter key.

3

Open the bonnet.

4

Remove the side panel

B,

lift the side upwards and outwards.

5

Fit the side panel, carefully slot the side panel into position. Lower and lock the bonnet.

B

399110

399380

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

8 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Seat Belt

Section 3

8 — 1

Checking the Seat Belt Condition and

Security

!

WARNING

When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years.

2-3-1-7/1

Inspect the seat belt for signs of fraying and stretching.

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

Check that the belt mounting bolts are undamaged, correctly fitted and tightened.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

9 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 1

You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine’s working life.

The machine must always be greased after pressure washing or steam cleaning.

!

WARNING

You will be working close into the machine for these jobs. Lower the attachments if possible. Remove the starter key and disconnect the battery. This will prevent the engine being started. Make sure the parking brake is engaged.

Chock all four wheels before getting under the machine.

2-3-2-1

Greasing should be done with a grease gun. Normally, two strokes of the gun should be sufficient. Stop greasing when fresh grease appears at the joint.

In the following illustrations, the grease points are numbered. Count off the grease points as you grease each one. Refit the dust caps after greasing.

Loader Arms

For each grease point shown, there is another on the other side of the machine.

Total 22 grease points.

% ^

3 4

7 8

!

@

£ $

1 2

5 6

9 0

& *

¤

⁄

( )

S260190

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

9 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 2

Backhoe & Quickhitch

22 Grease Points

Note:

Figure shows a typical boom and dipper arrangement.

^

%

*

(

)

&

⁄

¤

@

7

8

4

9

!

6

$

£

1

2

0

5

3

A340900

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

9 — 3

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 3

Front Axle (2 Wheel Drive Machines)

9 Grease Points Note:

Grease point

5

is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

3

4

5

1

2

6

7

8

9

S260200

Front Axle (4 Wheel Drive Machines)

5 Grease Points

Note:

Grease point

5

is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

1 2

5

4 3

1

3

9803/3280

2

Purchased from www.WorkshopManuals.co.uk

4

S260210

Issue 1

Section 3

9 — 4

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 4

Front Axle (All Wheel Steer Machines)

5 Grease Points

Note:

Grease point

5

is a remote grease point mounted on the side of the front nose (near the left front wheel).

1 2

1

2

Rear Axle (All Wheel Steer Machines)

4 Grease Points

5

3

4

3

S260220

4

1 2

3 4

9803/3280

Purchased from www.WorkshopManuals.co.uk

S260230

Issue 1

Section 3

9 — 5

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 5

Extending Dipper Driveshafts

Front Driveshaft

3 Grease Points

!

CAUTION

Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep

Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

5-3-1-9

3

2

1

Extend the dipper. Coat the runners with

Waxoyl

as shown.

S157500

9803/3280

S148000

Rear Driveshaft

3 Grease Points

1

3

2

S157511

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 3

9 — 6

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 6

6 — In — 1 Clamshovel

3 grease points each end —

Total 6 Grease Points

Loader Quickhitch

2 grease points each end —

Total 4 Grease Points

1 2

3 4

5 6

S089961

1

3

4

2

S257250

Stabilisers (Centremount Machines)

3 grease points on each stabiliser —

Total 6 Grease Points

3

2

1

9803/3280

S259390

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

9 — 7

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 7

Power Sideshift

Total 4 Grease Points

Note:

Release the kingpost clamps and lower the excavator to the ground before greasing.

Kingpost

9 Grease Points

Note:

Figure shows a centremount kingpost, greasing is same for sideshift kingpost.

Note

: It is recommended that grease points

2

and

3

are lubricated using a hand grease gun. The use of a power grease gun may result in the mounting plate being distorted.

2

1

9

1

4

2 3

3

4

S254690

5

6

7 8

A326770

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

9 — 8

www.WorkshopManuals.co.uk

Routine Maintenance

Greasing

Section 3

9 — 8

Knuckle (if fitted)

Refer to Backhoe greasing for the boom and dipper grease points.

Total 2 Grease Points.

Backhoe Quickhitch (Hydraulic)

!

CAUTION

Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep

Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

5-3-1-9

Coat the slide

A

with

Waxoyl.

4 Grease Points

2

1

S256440

4

1

A

2

3

S211750

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

10 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Tyres and Wheels

Section 3

10 — 1

Tyre Inflation

These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.

!

WARNING

An exploding tyre can kill, inflated tyres can explode if overheated. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work.

2-3-2-7

1 Prepare the Wheel

Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage.

2 Prepare the Equipment

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than

1.38 bar (20 psi) above the recommended tyre pressure. See Section F,

Technical Data

for recommended tyres and pressures for your machine.

Use an air hose fitted with a self-locking air chuck and remote shut-off valve.

3 Add the Air

Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do not over-inflate.

Checking the Wheel Nut Torques

On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

Every day, before starting work, check that the wheel nuts are tight.

The correct torques are shown in the table below.

Front — Nm

680

lbf ft

500

Rear — Nm

680

lbf ft

500

!

WARNING

If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

2-3-2-8

S089571

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

11 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Brakes

Section 3

11 — 1

Parking Brake Adjustment

1

Disengage the parking brake (lever horizontal).

2

Turn handle grip

E

clockwise, half a turn.

3

Test the parking brake, see Section G,

Service

Procedures

.

4

If the brake fails the test, repeat steps

1

,

2

and

3

. If there is no more adjustment and pin

F

is at the end of its travel get the brake checked by your JCB Dealer.

E

F

347581

Checking the Foot Brake Fluid Level

!

WARNING

Faulty brakes can kill. If you have to add oil to the brake reservoir regularly get the brake system checked by your

JCB Dealer. Do not use the machine until the fault has been put right.

2-3-2-5

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Remove the reservoir cap

A

and check the level. The

MAX and MIN marks are marked on the side of the reservoir

B

. If necessary, add fluid as in Step 3.

If the level has fallen below the MIN mark, get the system checked by your JCB Dealer.

!

WARNING

Using incorrect brake fluid could damage the system.

See Service Capacities and Lubricants in

MAINTENANCE Section. The fluid can harm your skin.

Wear rubber gloves. Cover cuts and grazes.

4-3-2-3

3

If required, carefully pour the recommended fluid (DO

NOT USE ORDINARY BRAKE FLUID) until it reaches the correct level.

4

Refit the reservoir cap. Wipe up any spillage.

B

A

399290

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

12 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Engine Air Filter

Section 3

12 — 1

Changing the Elements

!

CAUTION

The outer element must be renewed immediately if the warning light on the instrument panel illuminates.

2-3-3-1

Note:

Do not attempt to wash or clean the elements — they must only be renewed.

Note:

Do not run the engine with the dust valve

J

removed.

Note:

A new inner element must be fitted at least every third time the outer element is changed. As a reminder, mark the inner element with a felt tipped pen each time the outer element is changed.

1

Stop the engine.

2

Remove the engine side panel (left hand side).

3

If changing the inner element, cover the end of the hose to prevent rain and dirt from getting into the engine.

4

Depress clips

B

and lift off cover

C

. Remove outer element

D

. Take care not to tap or knock the element. If the inner element is to be changed, lift up pulls

E

and remove inner element

F

. On turbocharged engines, remove pulsation ring

L

.

5

Clean inside the canister

H

, pulsation ring

L

, cover

C

and dust valve

J

.

6

Insert the new elements into the canister, pushing them firmly in so that seals

G

and

K

are fully seated. On turbocharged engines, assemble the pulsation ring

L

into the cover, making sure that tongue

M

fits into slot

N

. Fit cover

C

with dust valve

J

at the bottom. Push the cover firmly into position and make sure it is secured by clips

B

.

Note

: Pulsation ring

L

is not fitted in this application.

7

Refit the induction hose to stub pipe

A

. Make sure that the wire is connected to the

Air Filter Blocked

switch.

A

9803/3280

G

H

C

K

J

F D

L N

M

E

N

M

B

Purchased from www.WorkshopManuals.co.uk

J

C

S257910

Issue 1

Section 3

13 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Engine Oil and Filter

Section 3

13 — 1

Checking the Oil Level

1

Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.

2

Open the bonnet,

see Engine Panels, Opening and

Closing the Bonnet.

3

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

A

.

4

If necessary, remove the side panel and add oil through filler

B

. Make sure that the dipstick and filler cap are fully inserted and tightened.

Changing the Oil and Filter

1

Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil.

Park the machine on firm ground.

!

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.

2-3-2-2

B

B

A

399290

2

Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.

3

Open the bonnet,

see Engine Panels, Opening and

Closing the Bonnet.

4

Drain the oil

:

!

CAUTION

Oil will gush from the hole when the drain plug is removed. Hot oil and engine components can burn you.

Keep to one side when you remove the plug.

13-3-1-15

a

Place a container of suitable size beneath the drain plug.

b

Remove drain plug

C

and its ‘ O’ ring. Let the oil drain out, then clean and refit the drain plug with a new ‘O’ ring. Tighten to 34 Nm (25 lbf ft).

5

Change the filter

: a

Unscrew the filter canister

D

. Remember that it will be full of oil.

b

Check that adapter

G

is secure.

c

Clean the filter head

F

.

d

Add clean engine lubricating oil to the new filter canister. Allow enough time for the oil to pass through the filter element.

e

Smear the seal

E

on the new filter with oil. Screw in the new filter canister — hand tight only.

6

Fill the engine to the max mark on the dipstick with new oil through the filler. See

Service Capacities and

Lubricants

for recommended oil grades. Wipe off any spilt oil. Check for leaks. Make sure the filler cap is correctly refitted.

7

Make sure the engine will not start and turn the starter switch to operate the starter motor until the oil pressure light is extinguished. (To make sure the engine will not start, remove the engine shut-off solenoid fuse, housed in the fuse box).

8

Insert the engine shut-off solenoid fuse and operate the engine. Check for leaks. When the engine has cooled, check the oil level.

D

F

G

E

S260260

C

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 3

14 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Engine Cooling System

Section 3

14 — 1

Checking the Coolant

!

WARNING

The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system.

2-3-3-3

1

Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.

2

Open the bonnet,

see Engine Panels, Opening and

Closing the Bonnet.

3

The coolant level should be between the COLD/MIN and the HOT/MAX marks on coolant reservoir

B

. Fill with pre-mixed water/antifreeze if necessary.

Changing the Coolant

!

WARNING

The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system.

2-3-3-3

A

B

1

Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.

2

Open the bonnet,

see Engine Panels, Opening and

Closing the Bonnet.

3

Carefully loosen cap

A

. Let any pressure escape.

Remove the cap.

!

CAUTION

Keep your face away from the drain hole when removing the drain plug.

2-3-3-4

4

Remove drain plug

C

and let the coolant drain out.

Make sure the drain hole is not blocked.

5

Disconnect the radiator hose at

D

and allow the coolant to drain. Flush the system using clean water.

6

Clean and refit plug

C

. Make sure it is secure.

Reconnect the radiator hose

7

Use the necessary mix of clean, soft water and antifreeze, see

Coolant Mixtures

. Fill to the COLD/MIN level on coolant reservoir

B.

8

Start the engine and run at idle to circulate the coolant, top up with coolant as necessary.

9

Refit the filler cap. Make sure it is tight.

10

Run the engine for a while, to raise the coolant to working temperature and pressure. Stop the engine.

Check for leaks.

Note:

Make sure the cab heater control is in the hot position. This will ensure the coolant mixture circulates through the entire cooling system.

399290

C

D

S148060

S260270

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 3

14 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Engine Cooling System

Section 3

14 — 2

Adjusting the Fan Belt

!

WARNING

Make sure the engine cannot be started. Disconnect the battery before doing this job.

2-3-3-5

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Loosen pivot fastening bolts

A

and

B

. Loosen adjustment link fastening bolts

C

and

D

.

3

Position the alternator so that there is 10 mm (3/8 in) slack at point

X

.

4

Tighten bolts

C

and

D

, then bolts

A

and

B.

Note:

If a new belt is fitted, the belt tension must be checked again after the first 20 hours of operation.

Cleaning the Cab Heater Filter

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the attachments to the ground and stop the engine.

2

Remove the cover retaining screws (2 off) and then remove the cover, item

E.

3

Knock loose dust off the filter

F

. Carefully blow compressed air through all the folds of the filter, blow in the opposite direction to the arrows marked on the filter.

Note:

The compressed air must be set at a pressure no greater than 7 bar (100 lb/in

2

).

4

Refit the cover

E

and secure with the retaining screws

(2 off).

A

B

C

D

X

S209411

E

F

S254720

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

15 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Fuel System

Section 3

15 — 1

Types of Fuel

Use good quality diesel fuel to get the correct power and performance from your engine. The recommended fuel specification for engines is given below.

Cetane Number:

45(minimum)

Viscosity:

2.5/4.5 centistokes at 40 °C (104 °F)

Density:

0.835/0.855 kg/litre

(0.872/0.904 lb/pint)

Sulphur:

Distillation:

0.5% of mass (maximum)

85% at 350 °C (662 °F)

Cetane Number

Indicates ignition performance. Fuel with a low cetane number can cause cold start problems and affect combustion.

Viscosity

Is the resistance to flow. If this is outside limits, the engine performance can be affected.

Density

Lower density will reduce engine power. Higher density will increase both engine power and exhaust smoke.

Sulphur

High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or

Australia.) If you have to use high sulphur fuel you must also use a highly alkaline engine lubricating oil; or change the normal oil more frequently.

Low sulphur fuels are commonly used throughout the world.

These fuels contain fewer lubrication additives. The fuel injection pumps fitted to the engine (with exception of

160TW, Euro 1 engine) are lubricated by the fuel; therefore using low sulphur fuel may, in the long term, affect the pump.

If you have to use low sulphur fuel you are advised to use a lubrication additive as recommended by your fuel supplier.

Distillation

This indicates the mixture of different hydrocarbons in the fuel. A high ratio of lightweight hydrocarbons can affect the combustion characteristics.

Fuel Standards

Consult your fuel supplier, JCB distributor about the suitability of any fuel you are unsure of.

Low Temperature Fuels

Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter.)

Flow improvers may also be available. These can be added to the fuel to reduce wax formation.

Fatty Acid M ethyl Ester Fuels as a replacement for

Diesel Fuels

Fuel resources such as Rape Methyl Ester and Soybean

Methyl Ester, collectively known as Fatty Acid Methyl Esters are being used as alternatives and extenders for mineral oil.

Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present.

Consult your JCB distributor for advice about the use of

Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.

Petrol

!

WARNING

Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.

INT-3-1-6

Advice

If you have to use non-standard fuels, contact your JCB distributor for advice on engine adjustments and oil change periods.

!

WARNING

Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.

INT-3-2-2

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

15 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Fuel System

Section 3

15 — 2

Filling the Tank

!

WARNING

Lower the loader arms and switch off the engine before refuelling. Do not permit operation of the machine controls while refuelling.

2-3-3-9

At the end of every working day, fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel.

The cap incorporates a side mounted barrel lock that is operated by the ignition/door key.

Fit the Cap

Once the key has been removed, the cap will simply rotate on the filler neck. To remove the cap from the filler neck, the key must be reinserted and the cap unlocked.

Draining the Filter

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Drain off any water in the element

A

by turning tap

B

Changing the Filter Element

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms and backhoe to the ground, stop the engine.

2

Unscrew the filter element

A

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

3

To assist with bleeding, fill the new filter element with fuel before fitting. Install new element

A

hand tight only.

Check for leaks.

4

Bleed the System.

A

B

399470

A

B

S233870

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 3

15 — 3

www.WorkshopManuals.co.uk

Routine Maintenance

Fuel System

Section 3

15 — 3

Draining the Sediment Bowl

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms and backhoe to the ground, stop the engine.

2

Look in bowl

A

. If it contains sediment, do Steps 3 to 6.

If there is water but no sediment, drain off the water by opening tap

B

. Make sure tap

B

is turned off and secure.

3

Support bowl

A

; unscrew nut

C

. Remove the bowl.

4

Wash the bowl. Use clean fuel.

5

Refit the bowl, make sure gasket is seated correctly.

6

Bleed the System.

Bleed the System

!

CAUTION

Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the system as detailed below.

2-3-3-7

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms and backhoe to the ground and stop the engine.

2

Set the starter key to the IGN position.

!

WARNING

Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

2-3-3-2

3

Operate the fuel lift pump priming lever

X

slowly, for approximately two minutes. The engine is now ready to start. If the engine runs smoothly for a short time, and then begins to run roughly or stops, check again for air in the fuel system. Check all seals and connections, especially in the low pressure side of the system.

Note:

If no fuel is moved when the fuel lift pump priming lever

X

is operated, then the pump diaphragm may have rested in a ‘maximum lift’ position. To move the diaphragm, use the starter key to turn the engine, then try the priming lever again.

A

C

B

S260120

X

S148060

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

16 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Synchro Shuttle Gearbox

Section 3

16 — 1

Checking the Oil Level

1

Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.

2

Open the bonnet,

see Engine Panels, Opening and

Closing the Bonnet.

3

Switch OFF the engine and remove the starter key, fill the transmission to maximum mark on dipstick/filler

A

.

Use only the recommended oil.

4

Start and run the engine slowly for a period not exceeding five minutes. This allows the oil to fill filter, pump, torque converter, oil cooler and hoses.

5

Switch OFF the engine and remove the starter key, wait approximately 20 seconds. Check the oil level and if required, fill to dipstick level.

A

Changing the Oil and Filter

The transmission oil should be drained through the suction strainer aperture to flush out any particles which fall off the strainer during its removal.

!

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.

2-3-2-2

1

Park the machine on level ground. Engage the parking brake. Lower the attachments to the ground. Stop the engine. Remove the starter key. Disconnect the battery.

!

CAUTION

When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer.

2-3-4-1

2

Place a container, of suitable size beneath the drain plug. Remove bolts

D

. Pull out the strainer

E

and its gasket

F

. Allow the oil to drain into the container.

3

Clean the strainer with a suitable solvent. Follow the solvent manufacturer’s instructions on safety.

4

Fit the strainer

E

and a new gasket

F

. Apply JCB

Threadlocker and Sealer to bolts

D

before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).

5

Unscrew and remove the filter

B

. Fit the new filter:

5.1

Smear seal

C

with transmission oil.

5.2

Screw the filter on until it just contacts the filter head.

5.3

Turn the filter at least another 3/4 of a turn.

6

Fill the system with new oil through the dipstick/filler

A

.

Do not fill past the top mark on the dipstick.

Note:

Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

C

B

F

D

E

399310

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 3

17 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Powershift Gearbox

Section 3

17 — 1

Checking the Oil Level

1

Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.

2

Open the bonnet, see

Engine Panels, Opening and

Closing the Bonnet.

3

Switch OFF the engine and remove the starter key, fill the gearbox to maximum mark on dipstick/filler

A

. Use only the recommended oil.

4

Start and run the engine slowly for a period not exceeding five minutes. This allows the oil to fill filter, pump, torque converter, oil cooler and hoses.

5

Switch OFF the engine and remove the starter key, wait approximately 20 seconds. Check the oil level and if required, fill to dipstick level.

A

A405230

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section 3

17 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Powershift Gearbox

Section 3

17 — 2

Changing the Oil and Filter

When draining JCB 760 Series Powershift gearboxes it is recommended that the oil is drained through the cover plate

A

to make sure that the debris collected in the transmission sump is flushed out. Draining oil through the sump plug will filter oil through the strainer and not flush out the debris.

!

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.

2-3-2-2

1

Park the machine on firm level ground, apply the park brake. Lower the loader arms, open the engine bonnet, raise the loader arms and fit the safety strut. Lower the excavator to the ground, switch OFF the engine and remove the starter key.

2

Apply the parking brake and disconnect the battery, remove the engine side panels.

3

Place a container of suitable size beneath the transmission to catch the oil.

4

Remove bolts

B

. Pull off cover plate

A

and gasket

C

, allow the oil to drain into the container. Be aware that the oil may be hot.

Note:

When the cover is removed oil will gush out. Keep to one side when you remove the cover plate.

5

Fit cover plate

A

and a new gasket

C

. Apply JCB

Threadlocker and Sealer to bolts

B

before fitting them.

Torque tighten the bolts to 28 Nm (20.5 lbf ft.).

6

Unscrew and remove the filter

D

. Fit the new filter:

6.1

Smear seal

E

with transmission oil.

6.2

Screw the filter on until it just contacts the filter head.

6.3

Turn the filter at least another 3/4 of a turn.

7

Fill the system with new oil through the dipstick/filler

F

.

Do not fill past the top mark on the dipstick.

8

On completion check for oil leaks.

Note:

Fit only a genuine supplied JCB filter, otherwise damage to the system may be incurred through contamination.

F

B

C

A

E

D

A405230

A405170

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section 3

18 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Hydraulic System

Section 3

18 — 1

Checking the Fluid Level

!

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 immediately.

INT-3-1-10/1

1

Position the machine on level ground. Set the loader shovel on the ground. Retract the extending dipper if fitted. Raise the boom, swing in the dipper and close the bucket. Stop the engine. Remove the starter key.

2

Look at the fluid level in the sight glass

A

. The level should be at the red mark (or above).

!

CAUTION

If the fluid in the tube appears cloudy, then water or air has entered the system. The hydraulic pump could be severely damaged if the machine is operated. Contact your JCB distributor immediately.

2-3-4-3

3

If the oil level is low, remove filler cap

B

and replenish with recommended hydraulic oil as required.

Hydraulic Tank Cap

The hydraulic tank breather (and filter) forms an integral part of the hydraulic tank cap

B

. Replace the cap (and breather filter) with a new one at the recommended interval, see

Service Schedules.

The cap incorporates a side mounted barrel lock that is operated by the ignition/door key. It is important to note that seal

C

must be in good condition and correctly installed in the cap.

Fit the Cap

Insert the key and turn anticlockwise

D

, screw the cap on until resistance is felt then turn a further quarter of a turn, turn the key clockwise

E

and remove the key. With the key removed the cap will rotate and can not be undone.

Remove the Cap

Insert the key and turn anticlockwise

D

, unscrew the cap.

B

D

C

B

A

E

A329760

399330

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

18 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Hydraulic System

Section 3

18 — 2

Changing the Filter Element

!

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 immediately.

INT-3-1-10/1

1

Position the machine on level ground. Roll the loader shovel forward and rest it on the ground. Retract the extending dipper if fitted. Close the backhoe bucket.

Swing in the dipper. Lower the boom until the bucket rests on the ground. Lower the stabilisers to the ground. Stop the engine. Remove the starter key.

2

Remove the element assembly

a

Remove screws

A

. Remove the cover plate

B

and gasket

C

*

Note:

If gasket

C

is a rubber type it can be reused provided it is undamaged. If the gasket is a cork type it must be discarded and a new gasket fitted on assembly.

b

Remove spring

D

.

c

Hold handle

E

and pull the element assembly from the hydraulic tank.

3

Remove the element from its canister.

a

Hold canister

F

.

b

Hold handle

E

and rotate the element

G

90° anticlockwise.

c

Pull on handle

E

, the element

G

should separate from its canister

F

. Discard the old element.

d

Remove and discard seal

H

.

e

Clean the inside of canister

F

.

New machines are fitted with a 5 micron filter element which must be replaced at the first 100 hour service with a 10 micron filter element.

4

Fit the new element.

a

Fit a new seal

H

.

b

Make sure that seal

J

is fitted in the new element.

c

Push the element

G

into its canister

F

and rotate the element 90° to lock it into position. Check that the element has locked into position by pulling on handle

E

.

d

Install the element assembly in the hydraulic tank.

*

e

Fit spring

D

and gasket

C

, (see ‘

Note’

at step 2).

f

Fit cover plate

B

and tighten screws

A

to 21 Nm

(15.5 lbf ft).

g

Check oil level and replenish as required through filler. Fit and tighten the filler cap as described on previous page.

J

E

G

D

A

B

C

H

F

399340

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section 3

18 — 3

www.WorkshopManuals.co.uk

Routine Maintenance

Hydraulic System

Section 3

18 — 3

Changing the Suction Strainer

!

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.

2-3-2-2

1

Position the machine on level ground. Roll the loader shovel forward and rest it on the ground. Retract the extending dipper if fitted. Close the backhoe bucket.

Swing in the dipper. Lower the boom until the bucket rests on the ground. Lower the stabilisers to the ground. Stop the engine. Remove the starter key and disconnect the battery.

2

Remove hydraulic tank filler cap.

3

Place a container beneath the hydraulic tank to catch the oil, remove drain plug and drain the hydraulic tank.

Make sure the container is large enough to hold the tank contents, see

Service Capacities and

Lubricants

.

4

Undo clips

A

and disconnect the hydraulic return pipe.

5

Using a 65mm A/F spanner unscrew suction strainer

B

and discard.

6

Fit a new filter assembly

B

, torque tighten to 15-20 Nm

(11-15 lbf ft).

7

Reconnect suction hose. Make sure the clips

A

are positioned 180° apart.

8

Refit drain plug, torque tighten to 100 Nm (74 lbf ft).

9

Refill hydraulic tank, fit and tighten the filler cap, see

Hydraulic Tank Cap

.

A

A

B

A334050

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

19 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Front and Rear Axle (All Wheel Steer Machines)

Section 3

19 — 1

Checking the Differential Oil Level

!

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.

2-3-2-2

!

CAUTION

The axle oil level must be checked with the machine level, otherwise a false indication of the amount of oil in the axle will be given.

16-3-5-3

1

Park the machine on level ground. Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Clean the area around fill/level plug

A

, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. Add recommended oil if necessary.

3

Clean and refit the plug and its washer.

Changing the Differential Oil

!

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.

2-3-2-2

1

Park the machine on level ground. Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Place a container of suitable size beneath plug

B

to catch the oil. Remove the drain plug

B

and its seal.

Allow oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Fit drain plug

B

and its washer. Tighten to

79 Nm (60 lbf ft).

3

Fill with recommended oil through fill/level hole

A

.

Clean and refit plug

A

and its seal. Tighten to 79 Nm

(60 lbf ft).

FRONT

S260420

B

A

REAR

A

B

S260430

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

19 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Front and Rear Axle (All Wheel Steer Machines)

Section 3

19 — 2

Checking the Hub Oil Levels

Check each hub separately.

1

Park the machine on level ground with the OIL LEVEL mark horizontal. There is a tolerance of 5 mm (0.2 in) above or below the horizontal.

2

Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

3

Clean the area around the fill/level plug

C

. Remove the plug. Oil should be level with the bottom of the hole. If necessary, add the recommended oil. Clean the plug before refitting it.

Changing the Hub Oil

The axle oil is used to lubricate the brake components and cool the brake plates.

It is important that the oil is changed regularly as specified in the service schedule — the lubricating properties of the oil will reduce as a result of brake wear.

Consult your JCB distributor for advice if necessary.

Change the oil in each hub separately

1

Set the machine level, with the tyres just clear of the ground. Manually rotate the wheels to bring the OIL

LEVEL mark on the hubs to the vertical position, with the fill/level plugs

C

at the bottom.

2 a

Place a container of suitable size beneath plug

C

to catch the oil.

b

Remove fill/level plugs

C

. Allow time for the oil to drain out.

3 a

Set

OIL LEVEL

marks to the horizontal.

b

Fill the hubs with recommended axle oil, through the fill/level holes

C

. Oil should be level with the bottom of the fill/level hole.

c

Clean and refit fill/level plugs

C

.

OIL

LEVEL

C

356040

C

S209320

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

19 — 3

www.WorkshopManuals.co.uk

Routine Maintenance

Front and Rear Axle (Two Wheel Steer Machines)

Section 3

19 — 3

The front axle procedures are the same as described on the previous pages (all wheel steer machines). Refer to the following procedures for checking and changing the oil on the rear axle.

Checking the Oil Level

!

CAUTION

The axle oil level must be checked with the machine level, otherwise a false indication of the amount of oil in the axle will be given.

16-3-5-3

1

Park the machine on level ground. Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Clean the area around fill/level plug

A

, then remove the plug and its sealing washer. Oil should be level with the bottom of the hole. Add recommended oil if necessary.

3

Clean and refit the plug and its washer.

Changing the Oil

The axle oil is used to lubricate the brake components and cool the brake plates.

It is important that the oil is changed regularly as specified in the service schedule — the lubricating properties of the oil will reduce as a result of brake wear.

Consult your JCB distributor for advice if necessary.

1

Park the machine on level ground so that the

‘OIL

LEVEL’

mark on one hub is at the bottom, as shown in fig. 1. Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Place a container of suitable size beneath fill/level plug

C

to catch the oil. Remove the fill/level plug

C

from the hub. Allow the oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Clean and refit the hub fill/level plug

C

.

3

Position the other wheel of the rear axle so that the

‘OIL LEVEL’

mark on its hub is at the bottom. Repeat step

2.

4

Place a container of suitable size beneath the drain plug

B

to catch the oil.

!

CAUTION

Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.

2-3-4-2

Remove the drain plug

B

. Allow the oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed). Clean and refit the drain plug

B

.

5

Remove fill/level plug

A

. Fill the axle with the specified quantity and recommended type of oil. Clean and refit fill/level plug

A

.

1

C

B

A

S145210

S209320

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section 3

21 — 1

Warning Symbols

The following warning symbols may be found on the battery.

Symbol

A289230

A289260

A289280

A289250

www.WorkshopManuals.co.uk

Routine Maintenance

Battery

Meaning

Keep away from children.

Shield eyes.

No smoking, no naked flames, no sparks.

Explosive Gas.

Battery acid.

Section 3

21 — 1

!

CAUTION

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

INT- 3- 1-14

!

WARNING

Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

INT-3-1-4

!

DANGER

Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.

INT-3-2-1/3

!

CAUTION

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

INT-3-1-12

!

WARNING

Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. M ake sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

INT-3-1-8

A289240

Note operating instructions.

A289270

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

21 — 2

www.WorkshopManuals.co.uk

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

Do the following if electrolyte:

GETS INTO YOUR EYES

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

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

5-3-4-3/1

Section 3

21 — 2

Checking the Electrolyte Level

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

!

WARNING

Do not top the battery up with acid. The electrolyte could boil out and burn you.

2-3-4-6

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe to the ground, raise the loader arms and fit the safety strut, see Loader Arm Safety Strut.

Switch OFF the engine and remove the starter key.

2

Remove the front grille

A

.

3

Remove battery cell covers. Look at the level in each cell. The electrolyte should be 6 mm (1/4 in) above the plates. Top up if necessary with distilled water or deionised water.

A

399350

9803/3280

S260640

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

21 — 3

www.WorkshopManuals.co.uk

Routine Maintenance

Battery

Section 3

21 — 3

Battery Isolator

To disconnect the battery from the machine electrics a battery isolator has been fitted.

!

CAUTION

Except in an emergency, do not use the battery isolator to switch OFF the engine. Failure to comply may result in damage to the electrical circuits.

INT-3-2-13

At the end of a working cycle or if the machine is being left unattended, provided the lights are not required, the battery must be isolated. Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switched on.

1

To isolate the battery turn the battery isolator key

A

in an anti-clockwise direction

B

and remove. Keep the key in a safe place and available for when the machine is next required.

2

To connect the battery insert the key

A

and turn in a clockwise direction

C

.

!

CAUTION

Before carrying out arc welding on the machine disconnect the battery and alternator to protect the circuits and components.

The battery must still be disconnected even if the battery isolator is fitted.

INT-3-1-13

C

B

A

A323611

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

23 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Hydraulic Oil Cooler

Section 3

23 — 1

Cleaning the Tubes/Fins

The hydraulic oil cooler is in front of the engine radiator. If the hydraulic oil cooler tubes/fins get clogged (by dirt and flies etc) the radiator and cooler will be less efficient.

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Unscrew bolts

A

. Lift off the radiator grille.

3

Brush off all debris from the cooler tubes and fins.

Make sure the loosened material is brushed out of the cooler enclosure.

4

Refit the radiator grille. Tighten bolts

A

evenly.

A

399360

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

25 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Stabiliser Legs (Sideshift Machines only)

Section 3

25 — 1

Wear Pads

The wear pads support and guide the inner leg section. They ensure that during extension and retraction the inner leg is kept central and has a minimum amount of ‘float’.

Upper wear pads

A

(4 off) are fitted to the top of the inner leg as shown. The upper pads are available in 3 sizes and are colour coded; 5mm (green); 6mm (red) and 7mm (blue).

Lower wear pads comprise adjustable pads

B

(2 off) and fixed pads

C

(2 off).

When pads

A

and

C

have worn to a minimum thickness of

0.5 mm (0.020 in.) they must be replaced with new ones. To replace the pads, the stabiliser inner leg must be removed

(contact your JCB Distributor).

It is important to note that lower pads

C

are designed to take most of the ‘loading’ during stabiliser leg operation, as a consequence these pads must be checked regularly for wear.

When replacing pads, it is recommended that the complete lower set of pads are replaced (items

B

and

C

). The top pads should be inspected and replaced as required.

Wear Pad Adjustment

Note: It is very important that the wear pads are adjusted at the correct service intervals, as the inner leg could contact the outer leg and scoring could occur. Scoring will dramatically reduce wear pad life.

Remove and clean away all debris that may have built up in stabiliser cavities.

As a guide, there should be approximately 1mm (0.039 in.) float between the stabiliser inner and outer leg.

Before adjusting the clearance make sure that the leg is raised clear of the ground but not fully retracted.

To adjust the clearance, screw pad

B

fully in until it just touches the inner leg and then back the pad off by one quarter of a turn.

Note:

Over-tightening the adjustable pad

B

will lock the pad in position, it will not be possible to back the pad off. If this should happen, operate the stabiliser leg as normal but be aware that pads

B

and

C

will wear more rapidly.

A

C

B

S273120

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

26 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Air Conditioning (if fitted)

!

WARNING

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

4-3-4-1/2

Adjusting the Compressor Drive Belt

!

WARNING

Make sure the engine cannot be started. Disconnect the battery before doing this job.

2-3-3-5

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Loosen bolts

A

,

B

and

C

. Position the compressor so that there is 10 mm (3/8 in) slack at point

X

.

3

Tighten bolt

A

, then bolts

B

and

C

.

X

A

B

Section 3

26 — 1

C

S209393

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

27 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Hose Burst Protection Valve (if fitted)

Section 3

27 — 1

The hose burst protection valves (if fitted) prevent the loader or backhoe falling in the event of a hose burst. These valves may be fitted on rams which raise or lower the loader arms, the boom or the dipper.

Checking Hose Burst Protection Valve

1

Raise the loader arms fully. Raise the boom to about

45°. Raise the dipper to the horizontal.

2

Stop the engine.

3

Using the control levers, try to lower the loader, boom and dipper. Push the levers fully to the ‘lower’ position.

If there is any movement, get the hydraulic system checked by your JCB distributor.

S320930

A

B

C

D

S170582

A171340

Lowering a Load

During normal operation, the engine must be running before a load can be lowered. The following paragraphs describe how to safely and correctly lower a load in the event of engine failure or a hose burst; we recommend that only a competent maintenance engineer perform the procedures.

After lowering a load do not use the machine until the manual over-ride screw has been reset (Loader HBPV) or a new end cap and valve assembly fitted (Boom HBPV) by a qualified engineer, otherwise the valve will not operate as intended.

!

DANGER

Do not stand underneath the raised load during the lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load. If you do not follow these precautions you or others could be killed or seriously injured.

2-3-5-3

Boom and Dipper Hose Burst Protection Valve (HBPV)

1

Remove cap

A

and pierce the warning label.

2

If a hose has burst, position a suitable container to catch the oil.

3

Insert a 6mm allen key into the socket head of screw

B.

Slowly turn the allen key in a clockwise direction until the load just begins move.

Burst hose

—

Lower the boom using screw

B

, turn the screw counter-clockwise to slow or stop the load from lowering.

Dead engine

—

Operate the control lever in the cab to lower the load.

Loader Hose Burst Protection Valve (HBPV)

1

Remove cap

C

from both HBPV check valves on the loader lift arms.

2

If a hose has burst, position a suitable container to catch the oil.

3

On the burst hose HBPV, insert a 5mm allen key into the socket head of screw

D.

Turn the allen key in a clockwise direction so that the screw winds fully in.

Repeat slowly for the opposite side as the load is now supported on this HBPV.

Note

: Count the number of full turns on each screw for resetting purposes.

4

Operate the control lever in the cab to lower the load.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

28 — 1

www.WorkshopManuals.co.uk

Routine Maintenance

Service Capacities and Lubricants

Section 3

28 — 1

ITEM

Fuel Tank

CAPACITY

Litres UK Gal

FLUID/LUBRICANT INTERNATIONAL

SPECIFICATION

150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D

Engine (Oil)

!

2 Wheel Steer Machines

— Build AR

— Build AK

11.0

10

4 Wheel Steer Machines

— Build AK 10.0

Engine (Coolant) 23.0

2.4

2.2

2.2

5.1

JCB Super Multigrade 15W/40

-10°C to +50°C (14°F to 122°F)

JCB Super Multigrade 10W/30

-15°C to +40°C (5°F to 104°F)

JCB Four Seasons Antifreeze

& Summer Coolant/Water

(see

Coolant Mixtures

)

SAE15W/40

CF-4/SG

SAE10W/30

CF-4/SG

ASTM D3306, BS6580

Syncro Shuttle (2WD)

∀

14.4

3.2

SAE10W

Syncro Shuttle (4WD)

∀

15.4

3.4

JCB Extreme Performance

(Below 40 °C, 104 °F)

JCB Extreme Performance

(Below 40 °C, 104 °F)

SAE10W

Powershift 6 speed

∀

16 3.5

Powershift 4 speed

Front Axle (4WD)

Housing (2WS)

∀

Housing (4WS)

#

Hubs (x2)

Rear Axle (4WS)

Housing

Hubs (x2)

Rear Axle (2WS)

Brake System

15.5

13

18

2.0

18

2.0

23

1.4

3.4

2.86

3.96

0.44

3.96

0.44

5.0

0.3

JCB Extreme Performance

(Below 40 °C, 104 °F)

JCB Extreme Performance

(Below 40 °C, 104 °F)

SAE10W

SAE10W

JCB HD90 Gear Oil

(without LSD) API-GL-5

JCB Special Gear Oil Plus

(with LSD) API-GL-4

Must be suitable for use with limited slip differentials (LSD).

JCB Special Gear Oil Plus

API-GL-4

Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

JCB Light Hydraulic Fluid

ISO VG15

!

CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Hydraulic System

∃

130 28.6

JCB High Performance Hydraulic Oil

ISO VG46

(Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32

(Below 38 °C, 100 °F)

ISO VG32

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 3

28 — 2

www.WorkshopManuals.co.uk

Routine Maintenance

Service Capacities and Lubricants

Section 3

28 — 2

ITEM

Grease Points

CAPACITY

Litres UK Gal

FLUID/LUBRICANT INTERNATIONAL

SPECIFICATION

—

JCB HP Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives or

JCB Special MPL-EP Grease

%

Lithium based NLGI No.2 consistency including extreme pressure additives

Extending Dipper —

Waxoyl

&

Electrical connections

—As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.

Power Sideshift Chains —

JCB Chain Lubricant

!

Note:

New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).

∀

Note:

The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system. Figures quoted within ±1.0 litre (0.22 U.K. gal).

∃

Note:

The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level indicator on hydraulic tank.

%

Note:

JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently.

&

!

WARNING:

Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

GEN-1-3

#

Note:

4WS axles with limited slip differential must use

JCB Special Gear Oil Plus

.

Coolant Mixtures

!

WARNING

Antifreeze can be harmful. Obey the manufacturers instructions when handling neat or diluted antifreeze.

7-3-4-4

The protection provided by JCB Four Seasons Antifreeze and Summer Coolant is shown below. If any other anti-freeze is used, refer to the manufacturer’s instructions and ensure that a corrosion inhibitor is included. DO NOT use solutions of more than 60% or less than 50% or damage to the cooling system will occur.

55% Solution —

Maintains circulation down to -36 deg C (-33 degF), protects against damage down to -41 deg C (-42 degF)

The strength of the anti-freeze solution must be checked at least once a year, preferably at the beginning of the cold period.

It is an advantage to leave the anti-freeze in all the year round as it gives continued protection against corrosion. Always renew the anti-freeze every two years. A 50% anti-freeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolants boiling point.

It should be noted that serious damage to the cooling system can occur if corrosion inhibitors are not used.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

i

Section A

www.WorkshopManuals.co.uk

Attachments

Section A i

Contents Page No.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

i

Section B

www.WorkshopManuals.co.uk

Body & Framework

Section B i

Contents

Service Tools

Slide Hammer Kit Procedure

Rivet Nut Tool Procedure

Technical Data

Air Conditioning (Option)

Basic Operation

Air Conditioning

— R-134a Refrigerant

— System Operation

— System Control

— Safety Procedures

Fault Finding

Air Conditioning

— General Fault Indications

— System Diagnosis

— Wiring Continuity Checks

Service Procedures

Air Conditioning

— Leak Testing

— Tightening Leaking Hoses

— Checking Refrigerant Charge Level

— Refrigerant Charging and Discharging

— Binary Pressure Switch Testing

— Condenser Matrix Cleaning

— Filters — Changing and Cleaning

— Compressor Drive Belt — Adjusting

Glazing

— Removing Broken Glass and Old Sealant

— Preparing and Installing New Glass

Cab ROPS/FOPS Structure — Checks

Engine Panels — Removing and Fitting

Stabiliser Leg — Wear Pad Adjustment

Extending Dipper — Wear Pad Adjustment

Sideshift — Hydraclamp Clearance Setting

Power Sideshift

— Wear Pad Renewal

— Chain Adjustment

Air Conditioning

HVAC*/Air Conditioning Unit

— Removal and Replacement

Blower Unit — Removal and Replacement

Freeze Protection Thermostat

— Removal and Replacement

Evaporator Matrix — Removal and Replacement

Binary Pressure Switch

— Removal and Replacement

*HVAC = Heating, Ventilation and Air Conditioning

Page No.

1 — 1

1 — 4

1 — 5

2 — 1

3 — 1

3 — 1

3 — 3

3 — 4

10 — 1

10 — 3

10 — 8

30 — 1

30 — 3

30 — 3

30 — 3

30 — 5

20 — 1

20 — 1

20 — 1

20 — 2

20 — 7

20 — 8

20 — 9

20 — 10

21 — 1

21 — 4

22 — 1

23 — 1

24 — 1

25 — 1

26 — 1

26 — 2

26 — 3

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

ii

Section B

www.WorkshopManuals.co.uk

Body & Framework

Section B ii

Contents

Loader Arms

— Removal and Replacement

Stabiliser Legs

— Removal and Replacement

Kingpost

— Removal and Replacement

Boom & Dipper

— Removal and Replacement

Hydraulic Tank

— Removal and Replacement

Power Sideshift Ram

Removal and Replacement

*

Cab Panels

— Removal and Replacement

Side Console

Front/Steering Console

Page No.

35 — 1

36 — 1

37 — 1

38 — 1

39 — 1

40 — 1

50 — 1

51 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section B

1 — 1 Service Tools

Section B

1 — 1

Hand Cleaner

— special blend for the removal of polyurethane adhesives.

JCB part number — 4104/1310

(454g; 1 lb tub)

S186240

Cartridge Gun

— hand operated — essential for the application of sealants, polyurethane materials etc.

JCB part number —

892/00845

S186270

12V Mobile Oven

— 1 cartridge capacity — required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket

(715/04300).

JCB part number — 992/12300

S186250

Folding Stand for

Holding Glass

essential for preparing new glass prior to installation.

JCB part number —

892/00843

S186280

240V Static Oven

— available with 2 or 6 cartridge capacity — required to pre-heat adhesive prior to use.

No plug supplied. Note: 110V models available upon request — contact JCB Technical Service.

JCB part number:

992/12400 — 2 Cartridge x 240V

992/12600 — 6 Cartridge x 240V

Glass Lifter

— minimum 2 off — essential for glass installation, 2 required to handle large panes of glass.

Ensure suction cups are protected from damage during storage.

JCB part number — 892/00842

9803/3280

S186260

Purchased from www.WorkshopManuals.co.uk

S186300

Issue 1

Section B

1 — 2 Service Tools

Section B

1 — 2

Wire Starter

— used to access braided cutting wire (below) through original polyurethane seal.

Cut- Out Knife

— used to remove broken glass.

JCB part number — 992/12800

JCB part number — 892/00848

S186310

S186340

‘L’ Blades

— 25 mm (1 in) cut — replacement blades for cut-out knife (above).

JCB part number — 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles)

— used with braided cutting wire (below) to cut out broken glass.

JCB part number — 892/00846

S186320

S186350

Braided Cutting Wire

— consumable heavy duty cut-out wire used with the glass extraction tool (above).

JCB part number — 892/00849

(approx 25 m length)

Long Knife

— used to give extended reach for normally inaccessible areas.

JCB part number — 892/00844

9803/3280

S186330

Purchased from www.WorkshopManuals.co.uk

S186360

Issue 1

Section B

1 — 3 Service Tools

Section B

Nylon Spatula

general tool used for smoothing sealants — also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

JCB part number — 892/00847

S186470

Rubber Spacer Blocks

— used to provide the correct set clearance between glass edge and cab frame.

JCB part number — 926/15500

(unit quantity = 500 off)

S186550

1 — 3

Slide Hammer Kit — 993/68100

1 :993/68101 Slide Hammer

2 :993/68102 End Stops

3 :993/68103 Adaptor — M20 x 5/8″ UNF

4 :993/68104 Adaptor — M20 x 1″ UNF

5 :993/68105 Adaptor — M20 x M20

11

6 :993/68106 Adaptor — M20 x M24

7 :993/68107 Bar — M20 x M20 X 800MM

8 :993/68108 Adaptor — M20 x 7/8″ UNF

9 :993/68109 Adaptor — M20 x M12

10 :993/68110 Adaptor — M20 x 5/8″ UNF (Shoulder)

11 :993/68111 Adaptor — M20 x 1/2″ UNF

2

2

5

2

1

6

4

9

8

7

3

10

S196910

826/01099

826/01101

826/01103

826/01102

826/01104

826/01105

M6 x 16mm Rivet Nut

M6 x 19mm Rivet Nut

M8 x 18mm Rivet Nut

M8 x 21mm Rivet Nut

M10 x 23mm Rivet Nut

M10 x 26mm Rivet Nut

Installation Tool Available from:

Bollhoff Fastenings Ltd.

Midacre

The Willenhall Estate

Rose Hill

Willenhall

West Midlands, WV13 2JW

9803/3280

Purchased from www.WorkshopManuals.co.uk

S261210

Issue 1

Section B

1 — 4

www.WorkshopManuals.co.uk

Body & Framework

Service Tools

Section B

1 — 4

Slide Hammer Kit Procedure

The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be ‘knocked through’. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins.

The adaptors

A

that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops, items

B

and

C

.

The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.

1

Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt.

2

Determine the thread size of the pivot pin and then fit the appropriate adaptor

A

as shown. Use the spanner flats

D

to securely fit the adaptor.

3

Fit an end stop

B

onto the other end of the adaptor (M20 thread size), make sure that the adaptor threads are fully engaged.

4

Fit the ‘slide bar’

E

into the end stop. Again make sure that the threads are fully engaged.

5

Fit the ‘ slide hammer’ , item

F

, onto the slide bar as shown.

6

Finally, fit another end stop, item

C

, at the end of the slide bar, as shown. The slide hammer kit is now ready to use.

7

To extract the pivot pin, slide the hammer along the bar until it contacts end stop

C

. Repeat this step until the pivot pin is released.

8

To remove the slide hammer kit, reverse the steps described above.

C

9803/3280

A

D

B

E

F

C

Purchased from www.WorkshopManuals.co.uk

S196900

Issue 1

Section B

1 — 5

www.WorkshopManuals.co.uk

Body & Framework

Service Tools

Section B

1 — 5

Rivet Nut Tool Procedure

A ‘Rivet Nut’ is a one piece fastener installed ‘blind’ from one side of the machine body/framework. The rivet nut is compressed so that a section of its shank forms an ‘upset’ against the machine body/framework, leaving a durable thread (see illustrations).

Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc.

Various sized rivet nuts are available, see the table below to determine the size of rivet nut to be used for particular applications.

If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed:

1

Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.

2

Screw the rivet nut onto the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the rivet nut, shown at

A

.

3

Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut, shown at

B

.

4

Insert the rivet nut (assembled to the tool) into the hole drilled in step

1

.

5

Hold handle

C

and at the same time draw the mandrel into the installation tool by turning nut

D

. The rivet nut will contract in length and form an ‘ upset’ (smooth bulge) seating itself against the body/framework (see inset

E

).

Note:

The thread of the rivet nut must not be stripped, take care when ‘upsetting’ the rivet nut.

6

Remove the installation tool.

C

B

A

E

D

Specifications (all dimensions in mm)

Rivet Nut

Thread

Diameter

M5

Rivet Nut

Outside

Diameter

7

Material

Thickness

0.25 — 3.00

Rivet

Length

(Total)

14.00

3.00 — 5.50

17.00

M6

M8

M10

9

11

13

0.50 — 3.00

16.00

3.00 — 5.50

19.00

0.50 — 3.00

18.00

3.00 — 5.50

21.00

1.00 — 3.50

23.00

3.50 — 6.00

26.00

Drill

Hole

Dia.

7.10

9.10

11.10

13.10

S150970

Note:

In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

2 — 1

www.WorkshopManuals.co.uk

Body and Framework

Technical Data

Section B

2 — 1

Air Conditioning (Option)

Binary Pressure Switch Settings

Low Pressure

High Pressure

1.96 bar (2.0 kgf/cm

27.5 bar (28 kgf/cm

2

2

28.4 lbf/in

400 lbf/in

2

2

)

)

Thermostatic Switch Settings

Cut out

Cut in

-0.6 °C (33.0 °F)

4.2 °C (39.5 °F)

Refrigerant

R-134a

Oil

PAG Oil

Quantities:

Condenser

Evaporator

Receiver Drier

Compressor

Hoses

1.4 Kg Maximum charge

1.5 fluid oz. (42.6 ml)

3.0 fluid oz. (85.2 ml)

0.3 fluid oz. (8.5 ml)

None — pre charged

If more than 4 metres of hose is replaced, then add 0.5 fluid oz. (15 ml) for every metre over 4 metres.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

3 — 1 Basic Operation

Section B

3 — 1

C

B

A

X

Y

D

G

H

J

F

E

A401370

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

3 — 2

Air Conditioning

Basic Operation

R-134a Refrigerant

Due to environmental concerns, the use of ozone depleting chlorofluorocarbons (CFCs) in air conditioning systems is being gradually phased out.

The R-12 refrigerant used in some systems contains CFCs and is now being replaced by a hydrofluorocarbon (HFC) refrigerant R-134a, which does not cause ozone depletion.

The refrigerant used in the 3CX air conditioning system is R-134a.

Air conditioning systems using R-134a refrigerant are not compatible with systems using R-12 refrigerant. No attempt should be made to charge R-134a systems with R-12 refrigerant.

System Operation

To maintain optimum operator comfort in warm climates or during seasons of high ambient temperature, the air conditioning system delivers cool, dehumidified air into the cab. Cooling is provided by passing the warm ambient air, together with recirculated air, over an evaporator matrix in the air conditioning unit.

The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system.

The major components of the system are the compressor

A

, condenser matrix

B

, receiver drier

C

, expansion valve

D

and evaporator matrix

E.

Section B

3 — 2

To operate the air conditioning, press switch

F

to switch the system on. Press switch

G

to operate the 3-speed heater fan. Rotate

H

to select the desired temperature. Control

J

enables the operator to select either recirculating air or fresh air from outside the machine. A combination of both is also obtainable.

Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. Three switches, connected in series, are included in the clutch supply line, all must be closed for the clutch and therefore the air conditioning system to operate.

The compressor

A

draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature.

High pressure refrigerant is forced from the compressor to the condenser

B

, which is mounted at the front of the engine. Ambient air is drawn across the condenser by the engine- driven cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content.

The refrigerant passes through the receiver drier

C,

which contains a desiccant to remove moisture from the system.

The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system.

The high temperature, high pressure refrigerant is forced by compressor action into the expansion valve

D

, which meters the amount of refrigerant entering the evaporator. In the expansion valve the refrigerant instantaneously expands to become a low pressure, low temperature liquid.

G

H

J

F

9803/3280

D

C

X

E

B

Y

A

A401390

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

3 — 3 Basic Operation

Section B

3 — 3

Air Conditioning

System Operation (cont’d)

The refrigerant is drawn through the evaporator matrix

E

by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator matrix by the blowers. Heat is transferred from the ambient and recirculated air to the refrigerant, causing the low pressure liquid to vaporise and become a low pressure gas. Moisture in the air condenses on the evaporator matrix and is drained away via condensate.

Cool de-humidified air is emitted through air vents into the cab.

The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed.

Service connection points

X

and

Y

adjacent to the compressor are provided for connecting the pressure gauge manifold, when charging/testing the refrigerant. Connection

X

high pressure (red) and connection

Y

low pressure (blue).

System Control

Control of the system is achieved by the cyclic action of the compressor’s electromagnetic clutch. When current is fed to the field coil of the compressor’ s clutch, a magnetic field develops between the field coil and the armature which pulls the field coil, complete with clutch assembly, onto the compressor’ s rotor. Since the clutch assembly is turned constantly by the crankshaft pulley drive belt, the compressor armature turns, starting the refrigeration cycle.

Current is fed to the field coil through three series switches whose contacts are controlled by the following:

a

The manual A/C ON/OFF switch

F

in the control console.

b

The freeze protection thermostat switch monitoring the evaporator temperature.

c

The high and low level binary pressure switch.

The ON/OFF switch

F

will start the refrigeration cycle provided that the ambient temperature in the cab is greater than 0°C and the refrigerant pressure remains within the specified limits.

The thermostat has its sensor inserted in the evaporator matrix. It controls the refrigeration cycle by switching the compressor clutch on and off to prevent freezing of the condensate on the evaporator matrix.

The high and low level binary pressure switch assembly is located adjacent to the expansion valve on the HVAC unit. If the refrigerant pressure exceeds the upper pressure limit specified or falls below the lower limit, the contacts will open and the clutch will disengage, closing down the refrigeration cycle.

Note:

Switch settings are given in the technical data, refer to

Technical Data — Air Conditioning (Option)

.

G

H

J

F

A401550

F

A/C ON/OFF Switch

G

Turn to switch on the 3-speed heater fan. Turn further clockwise for faster speeds. It functions only with the starter switch ON.

H

Temperature — Turn anti-clockwise to increase the heat.

J

Air Recirculation — Turn clockwise to recirculate air in the cab. Turn anti-clockwise for fresh air from outsde.

The control can be adjusted to give a combination of recirculated air and fresh air.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

3 — 4 Basic Operation

Safety Procedures

The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

!

WARNING

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 suitable trained person You can be severely frostbitten or injured by escaping refrigerant

4-3-4-1/2

!

CAUTION

Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged.

4-3-4-4

1

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. It is illegal to discharge the refrigerant into the atmosphere but as a precaution in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a well ventilated area.

2

Containers of refrigerant should be stored in a cool environment away from direct sunlight.

!

WARNING

Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit.

BF 1- 9

3 Do Not

perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m from hoses).

4 Do Not

steam clean refrigerant system components.

5

When charging or discharging the refrigerant system, no smoking or naked flames should be allowed in the immediate vicinity. The refrigerant does not give off a poisonous odour, however, when it comes into contact with a naked flame, a poisonous gas is produced.

6

When handling refrigerant, rubber gloves and goggles should be worn. Operators should ensure no refrigerant comes into contact with the skin. Particular care should be taken when connecting or disconnecting charging hoses or pressure switches. When these components are connected to the system, a short release of refrigerant occurs. This results in a high velocity, very cold gas being emitted from the connection point.

Section B

3 — 4

7

When checking the state of the refrigerant at the receiver drier sight glass, it is necessary to run the engine with the side panel removed and the bonnet raised. Extreme care must be taken to avoid moving engine parts such as fans, pulleys and belts.

8

Use caution when working near exposed evaporator fins. Painful cuts can be inflicted by the edges of the fins. Also, damage to the fins will reduce the efficiency of the system.

9

Make sure pressure cylinders are not over filled, particularly when recovering refrigerant.

10

Disconnect battery before doing any work.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 1 Fault Finding

Section B

10 — 1

Air Conditioning

The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment.

It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant pressure gauge should be used. However, leaks can be detected on the system by using soapy water applied to the suspected leak area and system pressure can be assessed by the state of refrigerant passing through the receiver drier sight glass. Following sections of the manual deal with the major components of the air conditioning systems and give further fault finding and maintenance information.

General Fault Indications

There are several indications that may help to determine the fault area on a system not working efficiently: a) Poor performance.

Low system pressure —

Condenser matrix air flow restricted —

Air filter blocked —

Compressor drive belt too slack —

Evacuate and recharge system.

Remove debris from around matrix using compressed air or low pressure water.

Remove and replace.

Adjust to correct tension.

b) Warm or slightly cool air emitted from unit.

d) Compressor clutch continually cuts out.

Expansion valve stuck open or closed c) Blower operates on fan Blower resistor failed speed 3 only.

Blower motor failed —

Blower does not operate.

Fuse blown —

Condenser matrix blockage —

Overcharging of refrigerant system —

Blocked expansion valve/condenser —

Renew expansion valve.

Renew resistor.

Renew complete blower unit.

Replace fuse and retest.

Remove debris from around matrix/renew condenser.

Evacuate and recharge system.

Clear blocked component .

Sight Glass Indications

An approximate indication of the condition of the refrigerant can be seen through the receiver/drier sight glass when the compressor is running. Refer also to

Service Procedures — Checking Refrigerant Charge Level

.

Clear — No fault indicated unless the system is unable to provide cool air. The indication then is that the system is completely discharged of refrigerant.

Foam or bubbles — Refrigerant low and in need of charging.

Clouded — Dessicant breakdown in the receiver-drier.

S201520

Note

: Sight glass indications cannot always give a positive identification of a problem. Further diagnosis, preferably by a refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 2 Fault Finding

Section B

10 — 2

Air Conditioning (cont’d)

No Air Conditioning

CHECK

1 Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?

2 Is the air conditioning (evaporator) blower working?

ACTION

YES: Check 2

NO: Reset controls and retest.

YES: Check 3.

NO: Check 4.

3 Is the compressor running (visual check of pulley/clutch)?

YES: Check 9.

NO: Check 5.

4 Is the air conditioning fuse(s) blown?

YES: Renew fuse(s) and retest.

NO: Check 8.

5 Is there a 12V supply to the pressure switch harness?

Refer to

Service Procedures — Pressure Switch Testing

YES: Check 6.

NO: Check 7.

6 Does the compressor clutch engage with pressure switch assembly bypassed?

Refer to

Service Procedures — Pressure Switch Testing

YES: Replace pressure switch assembly.

NO: Renew the compressor clutch and retest.

7 Does the clutch engage with thermostat switch bypassed?

8 Are blower switch and wiring OK?

9

10

11

Is sight glass indication OK?

Is condensor air flow blocked?

Is evaporator air flow blocked?

YES:

NO:

Renew thermostat switch and retest.

Check all electrical connections.

YES: Renew blower unit complete.

NO: Renew switch or wiring.

YES: Check 10.

NO: Charge check required by refrigeration engineer or suitably trained person.

YES: Clean condensor and radiator.

NO: Check 11.

YES: Clean filter and, if necessary the evaporator.

NO: Call in refrigeration engineer or suitably trained person.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

10 — 3

www.WorkshopManuals.co.uk

Body & Framework

Fault Finding

Section B

10 — 3

Air Conditioning — System Diagnosis

This section gives an overview of the following conditions:

Normally Functioning A/C System

Low R-134a Charge

Poor Refrigerant Circulation

No Refrigerant Circulation

Insufficient Cooling of Condenser

Air in System

Expansion Valve Improperly Mounted

Compressor Malfunction

Moisture in the System

Note:

Normal gauge readings will depend on system components and ambient conditions, make sure that the valves are closed and the readings are stable and that the system has a full charge.

The pressures on the manifold at 25 °C with the engine at

1500 RPM, the blower on maximum and the thermostat set to maximum, should be approximately:

Typically, the high pressure is 6 — 8 times the low pressure.

Normally Functioning A/C System

Gauge Readings:

Low Side Gauge —

Normal.

High Side Gauge —

Normal.

Other Indications:

Sight Glass —

Clear.

Discharge Air —

Cold.

LOW SIDE (Blue)

Normal

HIGH SIDE (Red)

Normal

LOW SIDE — 2.0 bar (2.0 kgf/cm 2 )(29 lbf/in 2 )

HIGH SIDE — 14.8 bar (15.1 kgf/cm 2 )(215 lbf/in 2 )

20

40

50

60

70 80

90

10

0

30

350

120

110

100

50

100

150

200 250

300

0

500 450

400

350

B

C

A

Component Key:

A

High Pressure/Temperature Gas.

B

Low Pressure/Temperature Gas.

C

High Pressure Liquid.

A401380

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 4

www.WorkshopManuals.co.uk

Body & Framework

Fault Finding

Section B

10 — 4

Air Conditioning

— System Diagnosis (cont’d)

Low R-134a Charge

Gauge Readings:

Low Side Gauge —

Low.

High Side Gauge —

Low.

Other symptoms:

Sight Glass —

Bubbles continuously visible.

Diagnosis:

System slightly low on R- 134a, due to leak or incorrect charge.

Correction:

1.

Leak test system.

2.

Evacuate A/C system.

3.

Repair system leaks.

4.

Charge system with R-134a.

5.

Operate system and check performance.

LOW SIDE (Blue)

Low

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

Low

50

100

150

200 250

300

0

350

500

450

400

LOW SIDE — 0.76 bar (0.77 kgf/cm 2 )(11 lbf/in 2 )

HIGH SIDE — 8.3 bar (8.5 kgf/cm 2 )(121 lbf/in 2 )

A268030

Poor Refrigerant Circulation

Gauge Readings:

Low Side Gauge —

Zero to negative.

High Side Gauge —

Low.

Other symptoms:

Receiver-Drier —

Frost on tubes from receiver-drier to evaporator unit.

Diagnosis:

Refrigerant flow obstructed by dirt, receiver-drier clogged.

Correction:

1.

Evacuate A/C system.

2.

Replace receiver-drier.

3.

Charge system with R-134a.

4.

Operate system and check performance.

LOW SIDE (Blue)

Zero to negative

40

50

60

70 80

90

20

10

0

30

350

120

110

100

HIGH SIDE (Red)

Low

50

100

150

200 250

300

350

0

500 450

400

LOW SIDE — -1.0 bar (-1.1 kgf/cm 2 )(-15 lbf/in 2 )

HIGH SIDE — 5.4 bar (5.5 kgf/cm 2 )(78 lbf/in 2 )

A268040

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 5

www.WorkshopManuals.co.uk

Body & Framework

Fault Finding

Section B

10 — 5

Air Conditioning

— System Diagnosis (cont’d)

No Refrigerant Circulation

Gauge Readings:

Low Side Gauge —

Zero to negative.

High Side Gauge —

Low.

Other symptoms:

Receiver-Drier —

Frost or moisture on tubes before and after receiver-drier.

Diagnosis:

Refrigerant flow obstructed by dirt, moisture or gas leakage from expansion valve heat sensing tube.

Correction:

1.

Evacuate A/C system.

2.

Check heat sensing tube at expansion valve.

Replace expansion valve if necessary.

3.

Remove expansion valve and attempt removal of dirt. If dirt cannot be removed, replace expansion valve.

4.

Replace receiver-drier.

5.

Charge system with R-134a.

6.

Operate system and check performance.

LOW SIDE (Blue)

Zero to negative

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

Low

50

100

150

200 250

300

0

350

500 450

400

LOW SIDE — -1.0 bar (-1.1 kgf/cm 2 )(-15 lbf/in 2 )

HIGH SIDE — 5.4 bar (5.5 kgf/cm 2 )(78 lbf/in 2 )

A268050

Insufficient Cooling of Condenser or Refrigerant

Overcharge

Gauge Readings:

Low Side Gauge —

High.

High Side Gauge —

High.

Other symptoms:

Sight Glass —

No bubbles visible even at lower engine RPM.

Diagnosis:

Refrigerant overcharge, condenser cooling fins clogged with dirt or cooling fans malfunctioning.

Correction:

1.

Clean condenser cooling fins.

2.

Check cooling fan operation.

3.

Evacuate A/C system.

4.

Charge system with R-134a.

5.

Operate system and check performance.

LOW SIDE (Blue)

High

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

High

50

100

150

200 250

300

350

0

500

450

400

LOW SIDE — 3.0 bar (3.0 kgf/cm 2 )(43 lbf/in 2 )

HIGH SIDE — 22.1 bar (22.5 kgf/cm 2 )(320 lbf/in 2 )

A268060

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 6

www.WorkshopManuals.co.uk

Body & Framework

Fault Finding

Section B

10 — 6

Air Conditioning

— System Diagnosis (cont’d)

Air in System

Gauge Readings:

Low Side Gauge —

High.

High Side Gauge —

High.

Other symptoms:

Sight Glass —

Bubbles visible during system operation.

Pipes —

Low pressure pipes are hot to the touch.

Diagnosis:

Air is present in the system, possibly from inadequate evacuation procedure.

Correction:

1.

Evacuate A/C system.

2.

Check compressor oil for contamination. Check compressor for proper oil amount. Correct if necessary.

3.

Charge system with R-134a.

4.

Operate system and check performance.

LOW SIDE (Blue)

High

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

High

50

100

150

200 250

300

0

500 450

400

350

LOW SIDE — 2.8 bar (2.8 kgf/cm 2 )(40 lbf/in 2 )

HIGH SIDE — 22.1 bar (22.5 kgf/cm 2 )(320 lbf/in 2 )

A268070

Expansion Valve Improperly M ounted or Heat

Sensing Tube Defective (Opening Too Wide)

Gauge Readings:

Low Side Gauge —

High.

High Side Gauge —

High.

Other symptoms:

Pipes —

Large amount of frost or moisture on low side pipes.

Diagnosis:

Excessive refrigerant in low side pipes possibly from expansion valve being opened too wide.

Correction:

1.

Leak test system.

2.

Evacuate A/C system.

3.

Repair system leaks.

4.

Charge system with R-134a.

5.

Operate system and check performance.

LOW SIDE (Blue)

High

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

High

50

100

150

200 250

300

350

0

500

450

400

LOW SIDE — 3.5 bar (3.5 kgf/cm 2 )(50 lbf/in 2 )

HIGH SIDE — 22.1 bar (22.5 kgf/cm 2 )(320 lbf/in 2 )

A268080

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 7

www.WorkshopManuals.co.uk

Body & Framework

Fault Finding

Section B

10 — 7

Air Conditioning

— System Diagnosis (cont’d)

Compressor Malfunction

Gauge Readings:

Low Side Gauge —

High.

High Side Gauge —

Low.

Diagnosis:

Internal compressor leak or compressor mechanically broken.

Correction:

1.

Evacuate A/C system.

2.

Repair or replace compressor.

3.

Charge system with R-134a.

4.

Operate system and check performance.

LOW SIDE (Blue)

High

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

Low

50

100

150

200 250

300

0

350

500 450

400

LOW SIDE — 4.9 bar (5.0 kgf/cm 2 )(71 lbf/in 2 )

HIGH SIDE — 8.3 bar (8.5 kgf/cm 2 )(121 lbf/in 2 )

A268090

Some Moisture in the System

Gauge Readings:

Low Side Gauge —

Normal, then sometimes drops to below zero.

High Side Gauge —

Normal, then sometimes goes high.

Diagnosis:

Moisture in system freezes, temporarily stopping cycle, normal system operation returns when ice melts.

Correction:

1.

Evacuate A/C system.

2.

Replace receiver-drier.

3.

Remove moisture by repeatedly evacuating system.

4.

Charge system with R-134a.

5.

Operate system and check performance.

LOW SIDE (Blue)

Normal to low

20

40

50

60

70 80

90

10

0

30

350

120

110

100

HIGH SIDE (Red)

Normal to high

50

100

150

200 250

300

0

350

500 450

400

LOW SIDE — -2.1 bar (-2.1 kgf/cm 2 )(-30 lbf/in 2 )

HIGH SIDE — 14.8 bar (15.0 kgf/cm 2 )(214 lbf/in 2 )

A268020

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

10 — 8 Fault Finding

Section B

10 — 8

Air Conditioning (cont’d)

Wiring Continuity Checks

Use the illustration below to complete continuity checks on the HVAC/air conditioning system and heater harness wires.The

harness connects to the main machine harness via connector

1

. Refer also to the main machine circuit diagram in Section C

Electrics

.

Component Key:

1

Main Machine Harness Connector

2

Air Conditioning ON/Off Switch

2A

Panel Illumination Bulb

2B

Switch Illumination Bulb

3

Blower Switch

4

Binary Pressure Switch

5

Freeze Protection Thermostat

6

Blower Speed Resistor

7

Blower Unit Motor

1

3

A B

2

4 5

6

M

7

A401410

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 1 Service Procedures

Section B

20 — 1

Air Conditioning

Leak Testing

Note

: The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area.

Hose or pipe connections are likely leakage points of any refrigerant circuit.

To test for leaks in the high pressure side of the system i.e.

from the compressor output to the expansion valve, run the air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector.

To test for leakage in the low pressure side of the system, switch off the air conditioning and leave for a few minutes before testing.

!

WARNING

Leak testing in Air Conditioning systems should be carried out only in a well ventilated area.

BF 1-2

Tightening Leaking Hoses

!

WARNING

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.

4-3-4-1

The refrigerant hoses have crimped ferrule end fittings. The hose connectors have an ‘ O’ ring seal which compresses when the connection is tight, creating an air tight seal.

Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion valve

(the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes).

If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to de-gas the system and renew the connector ‘O’ ring seal.

The ‘O’ rings used on an R-134a refrigerant system are of an

HNBR compound and are colour coded green. These ‘ O’ rings must be used as some ‘O’ ring materials can become porous to R-134a systems, resulting in leakage.

Checking Refrigerant Charge Level

The pressure in the system, i.e. the refrigerant charge level can be determined by checking the state of refrigerant at the receiver drier sight glass.

If the level of charge is correct the sight glass will be clear. If the charge is low bubbles will be seen. Bubbles may also be an indication of inadequate cooling, due to a restriction of air flow around the condenser coil. Recharging of the system should be carried out by an air conditioning engineer. Check refrigerant charge level as follows:

1

Park the machine on firm, level ground. Lower the backhoe and loader to the ground.

2

Remove the starter key.

3

Remove the front grille.

!

WARNING

When the engine is turning, there are parts rotating in the engine compartment.

Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.

When the engine is turning, keep clear of rotating parts.

2-3-3-10

4

Start the engine and run at idle. Switch air conditioning

ON to circulate refrigerant.

5

Check refrigerant charge level at sight glass

A

.

A

S190460

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

20 — 2 Service Procedures

Section B

20 — 2

Air Conditioning

— Refrigerant Charging and Discharging

Note:

The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.

!

WARNING

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 suitable trained person. You can be severely frostbitten or injured by escaping refrigerant.

4-3-4-1/2

Refrigerant Recovery

The recovery process clears the system refrigerant proir to servicing or for refrigerant renewal.

1

Ensure that the engine is OFF and the starter key removed.

2

Connect the manifold to the system as shown, with the blue hose connected to the system low pressure port.

DO NOT connect the red hose. Make sure that both valves are closed.

3

Connect the yellow hose to the ‘Javac’ unit filter.

4

Connect the filter to the ‘Javac’ unit.

5

Connect the ‘Javac’ unit to an empty receiver bottle.

Weigh the bottle before and after filling to assess system capacity.

6

Switch on ‘Javac’ unit and open the low pressure manifold valve.

7

The ‘Javac’ unit will automatically switch off when a pressure balance exists between the system and the receiver bottle. Switch off ‘Javac’at main switch, but leave the system connected. Switch on after 10 minutes, the ‘Javac’ will restart if residual pressure remains.

8

Close valves and remove equipment.

Valve OPEN

IN

‘Javac’ Unit

Lo

To system Low

Pressure port.

Filter

DIS

Hi

To system High

Pressure port.

Valve CLOSED

Scales

Refrigerant

Cylinder

A396820

Notes:

DO NOT fill the receiver bottle to more than 80% by weight.

DO NOT re-use refrigerant unless you are aware of its purity.

If the high pressure warning light on the ‘Javac’ unit comes on, throttle back the manifold low pressure valve to provide a restriction.

The JCB recommended ‘Javac’ unit only recovers refrigerant as a gas. Other units can recover refrigerant as a liquid and/or gas. ALWAYS check manufacturers instructions before using.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

20 — 3 Service Procedures

Section B

20 — 3

Air Conditioning

— Refrigerant Charging and Discharging

Note:

The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.

!

WARNING

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 suitable trained person. You can be severely frostbitten or injured by escaping refrigerant.

4-3-4-1/2

Evacuating (Vacuuming)

This procedure follows on from the ‘Recovery’ process and is necessary to ensure proper refilling of the system with refrigerant.

To avoid leakage in the vacuum system itself, DO NOT use extensions to the yellow hose (use standard 2 metre length).

1

Recover all refrigerant from the system as described in

Refrigerant Recovery

.

2

Close all valves and connect the manifold as shown.

Connect the blue hose to the system low pressure port and the red hose to the high pressure port.

3

Connect the yellow hose to the vacuum pump.

4

Open manifold valves.

5

Switch on the vacuum pump until 740mm (29 in) mercury vacuum reads on both gauges.

6

Maintain suction for approximately 30 minutes.

7

Close valves and remove equipment.

Lo

To system Low

Pressure port.

Valve OPEN

CPSVG100

Vacuum guage

(If used)

Hi

To system High

Pressure port.

Valve OPEN

Vacuum Pump

A396780

Notes:

If the vacuum falls rapidly the system is leaking. Check all connections and reseal. If the point of leakage is not obvious, recharge the system and test again. Refer to

Service Procedures, Air Conditioning — Leak Testing

.

Achievable vacuum will vary with altitude. Maximum gauge reading will be 25mm (1 in) less for every 305 metres ( 1000 feet) above sea level.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 4 Service Procedures

Section B

20 — 4

A396790

Electronic Vacuum Gauge

The CPS VG100 vacuum gauge is an electronic type using

LED’s to indicate various states of vacuum. It is used in place of or to supplement the gauge on the vacuum pump.

Before connecting into the system switch on to check that the first LED lights to show that the battery is in good condition.

Note:

The indicator lights show pressure in inches of mercury (Hg) and vacuum in microns (0.001mm Hg).

1000µ

600µ

400µ

200µ

25µ

ATM/BAT

15’’/510mbar

29’’/980mbar

8000µ

Normal atmospheric pressure reading.

Battery condition.

381mm (15 in)Hg. Partial vacuum —

Vacuum system is operating.

736mm (29 in)Hg. No vacuum drawn —

Possible system leakage.

8.0mm (0.31 in)Hg. Partial vacuum —

If the reading does not progress the system may have a slow leak.

1.0mm (0.039 in)Hg. Deeper vacuum.

0.6mm (0.023 in)Hg. Deep vacuum.

0.4mm (0.015 in)Hg. Deep vacuum.

0.2mm (0.0078 in)Hg. Deep vacuum.

0.025mm (0.00098 in)Hg. Pump Test.

Maximum sustainable vacuum.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 5 Service Procedures

Section B

20 — 5

Air Conditioning

— Refrigerant Charging and Discharging

Note:

The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.

!

WARNING

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 suitable trained person. You can be severely frostbitten or injured by escaping refrigerant.

4-3-4-1/2

Relubricating

Pre-lubrication is essential after recovering system refrigerant, vacuuming and component flushing.

The system should be evacuated to a vacuum of 740mm (29 in) of mercury before re-lubricating.

1

Ensure that the engine is OFF and the starter key is removed.

2

Close all valves and connect the manifold as shown, with the blue hose connected to the oil injector and the red hose to the system high pressure port.

3

Connect the yellow hose to the vacuum pump.

4

Connect the other end of the oil injector to the system low pressure point.

5

Switch on the vacuum pump and open the high pressure side valve.

6

Unscrew the oil injector cap and add the specified quantity of refrigerant oil.

7

When 740mm (29 in) mercury shows on the vacuum gauge, open the oil injector valve to allow the oil into the system.

8

If more oil is needed repeat the above procedure. The quantity of oil should be the same as that taken out during the ‘

Recovery

’ procedure.

To system Low

Pressure port.

Valve OPEN

Oil Injector

Lo

Oil injector valve —

Open when full vacuum is obtained.

Hi

Vacuum Pump

Notes:

Use only PAG oil in R-134a systems.

To system High

Pressure port.

Valve OPEN

To system Low

Pressure port.

A396800

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 6 Service Procedures

Air Conditioning

— Refrigerant Charging and Discharging

Note:

The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.

!

WARNING

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 suitable trained person. You can be severely frostbitten or injured by escaping refrigerant.

4-3-4-1/2

Charging

This procedure is industry recommended practice for refilling air conditioning systems with refrigerant.

Evacuate the system beforehand to 740mm (29 in) of mercury.

1

Close all valves and connect the manifold as shown.

Connect the blue hose to system low pressure and the red hose to system high pressure. Connect the yellow hose to the refrigerant cylinder.

2

Invert single valve cylinder on the scales and zero the scale reading (see

Notes:

for twin valve cylinders).

3

Slowly open the high pressure valve and allow the vacuum to draw-in refrigerant to the specified weight for the system. Refer to

Technical Data

.

4

Close all valves and remove the equipment.

Lo

To system Low

Pressure port.

Valve CLOSED

Refrigerant

Cylinder

Thermal Blanket

Scales

Hi

Section B

20 — 6

To system High

Pressure port.

Valve OPEN

A396810

Notes:

Add refrigerant as a LIQUID, not as a gas. Some refrigerant cylinders have separate valves for gas and liquid. Be sure to connect to the liquid port when following the above procedure.

Refrigerant can be used either in gas or liquid form. If recharging with gas follow the manufacturers instructions and recharge only via the low pressure port. DO NOT use liquid refrigerant at the low pressure port.

Add refrigerant until the scales indicate the specified weight for the system or the weight obtained when the system refrigerant was previously recovered.

To speed up the process a thermostatically controlled thermal blanket can be used around the replenishing cylinder.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

20 — 7 Service Procedures

Air Conditioning

Binary Pressure Switch Testing

The binary pressure switch assembly comprises a low pressure switch designed to open at 1.96 bar (28.4 lbf/in

2

) and a high pressure switch designed to open at

27.5 bar (400 lbf/in 2 )

When the refrigerant pressure is within the 1.96 and 27.5 bar limits the switches will be closed and providing the freeze protection thermostat and ON/OFF switches are closed, a current will be supplied to the field coil of the clutch.

Through electro- magnetic action the field coil clutch will be pulled towards the compressor’s clutch and the refrigeration cycle will commence.

If the fault finding table indicates that the pressure switch assembly is defective the fault may be electrical or due to incorrect system pressure.

Refer to

Checking Refrigerant Charge Level

. If the refrigerant charge level is OK use the following electrical test procedures.

1

Switch the engine off so that the air conditioning system cannot operate.

2

Disconnect the binary pressure switch harness from the side console harness and connect an external 12V power supply between the pressure switch harness connector and chassis. If both pressure switches are working correctly, and the system is at the correct charge level, the compressor clutch will operate.

If the compressor clutch does not operate with the external power supply, one of the pressure switches in the assembly is faulty or the level of refrigerant charge is insufficient to close the low pressure switch.

3

Replace the pressure switch assembly. Refer to

Binary

Pressure Switch — Removal and Replacement

. If the clutch still fails to operate check all electrical connections.

Section B

20 — 7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 8 Service Procedures

Section B

20 — 8

Air Conditioning

Condenser Matrix

It is likely that over a period of time, because of the machine’ s working environment, the airflow around the condenser matrix will become restricted due to a build up of airborne particles.

If the build up of particles is severe, heat dissipation from the refrigerant to the air will be significantly reduced, resulting in poor air conditioning performance.

In extreme cases, over pressurisation of the system occurs, causing the high pressure cut out switch to operate and switch off the system.

High pressure cut out can also be caused by an internal blockage of the condenser matrix.

Condenser Matrix Cleaning

Take care not to damage the condenser fins or tubes.

Damaged fins must be straightened out to ensure a good airflow through the matrix.

1

Park the machine on firm level ground. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Remove the starter key.

3

Remove the front grille.

4

Remove both side panels.

5

Support the condenser

1

.

6

Undo the nuts and bolts

2

at the three mounting brackets

3

.

7

Remove the screws

4

fixing the condenser to the mounting brackets. Remove the brackets

3

to enable the condenser to be moved away from the radiator.

This can be done without removing the hoses i.e. with the system fully charged.

8

With the condenser fully supported, use compressed air or low pressure water to backflow through the matrix fins. Take care not to damage the fins.

9

Refit the condenser matrix by reversing the removal procedure. Refit both side panels and bonnet.

10

Run the air conditioning and check cooling performance.

4

1

4

2

3

9803/3280

A401500

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 9 Service Procedures

Air Conditioning

Filters — Changing and Cleaning

Air Intake Filter

1

Stop the engine and remove the starter key.

2

Remove Screws

D

, air intake cover

E

and filter

F.

Clean filter element using compressed air. Refit filter into the cover and refit.

Section B

20 — 9

E

F

D

S190470

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

20 — 10

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

20 — 10

Air Conditioning

Compressor Drive Belt — Adjusting

1

Park the machine on firm level ground. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

2

Remove the starter key.

!

WARNING

Make sure the engine cannot be started. Disconnect the battery before doing this job.

2-3-3-5

X

C B

3

Raise the Bonnet

4

Remove both Side Panels

5

Loosen pivot fastening bolt

A

. Loosen adjustment link fastening bolts

B

and

C

.

6

Position the compressor so that there is approximately

10 mm (3/8 in) slack at point

X

midway along the belt.

7

Tighten bolts

A

,

B

and

C

. Make sure that bolt

A

is the last to be tightened.

Note:

If a new belt is fitted, check the belt tension after the first 20 hours of operation.

A

S209393

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

21 — 1

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

21 — 1

Glazing

The glass panes on the cab are all direct glazed.

Direct Glazing

The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken:

1

Always wear safety glasses during both removal and replacement.

2

Use protective gloves — heavy duty leather gauntlet type gloves when cutting out the broken glass; ‘ non-slip’ type gloves when handling/moving panes of glass; surgical type gloves when using the polyurethane adhesives.

3

Wear protective overalls.

4

DO NOT smoke — the activators and primers used in the procedures are highly flammable.

5

Do not attempt to handle or move panes of glass unless you are using glass lifters (see

Service Tools

).

Removing the Broken Glass and Old Sealant

Several special tools are required to successfully complete the removal and replacement procedures. Reference is made to the tools in the text. The majority of these tools can be obtained locally and the remainder from JCB Service

(see

Service Tools

).

The work must only be carried out in a dry, frost free environment. A protective canopy may be required or the machine/frame must be moved to a sheltered area. In damp or wet conditions, hinged doors and window frames can be removed from the machine and taken to a more suitable

(dry) environment.

Glass should not be replaced at temperatures below 5°C

(41°F).

Note:

The front screen glass is laminated, the other glass is toughened. If a laminated pane breaks it will stay in one piece even though the glass is cracked. A toughened pane will shatter and fall apart. The method of removal of the glass depends upon which type it is. See WARNING below.

!

WARNING

Always wear safety glasses when removing or installing screen glass. Never use a power operated knife when removing the sealant around a toughened glass screen.

The action of the knife could cause particles of glass to be thrown with sufficient force to cause serious injury, even when safety glasses are being worn. Use only hand operated tools when working with toughened glass.

BF 2-3/1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

21 — 2

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

21 — 2

Direct Glazing (cont’d)

Removing the Broken Glass and Old Sealant (cont’d)

1

Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.

2 a

Laminated glass — leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.

b

Toughened glass — remove as much of the shattered glass as possible prior to cutting out the old sealant.

3

Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this:

a

Pneumatic Knife

A

provides one of the easiest methods of removing the sealant around laminated glass. The tool, powered by compressed air, should be sourced locally.

Note

: This tool must not be used on toughened glass (see

WARNING on previous page).

(i) Press the handle to start the knife blade oscillating.

(ii) Insert the knife blade into the sealant.

(ii) Slowly move the knife along the sealant with the blade positioned as close to the glass as possible.

Do not allow the knife blade to overheat or the sealant will melt.

b

Braided Cutting Wire and Handles

B.

This method uses a 3-core wire, a wire starter tube and two handles (see

Service Tools

).

(i) Insert the steel tube

C

into the old sealant on the inside of the glass.

(ii) Insert the braided cutting wire

D

down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire.

(iii) Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass.

(iv) Secure each end of the braided cutting wire in the special handles

E

.

(v) Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant.

A

B

D

D

C

C

E

D

E

S186380

S189870

S189880

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

21 — 3

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

21 — 3

Direct Glazing (cont’d)

Removing the Broken Glass and Old Sealant (cont’d) c

Cut-out Knife

F

. The cut-out knife can be used as a left handed or right handed tool. For the knife and its replaceable blades, refer to

Service Tools

.

(i)

(ii)

Insert the knife blade into the sealant.

Make sure that the blade of the knife is against the glass as shown at

G

.

(iii) Use the ‘pull-handle’ to pull the knife along and cut out the old sealant.

d

Craft Knife

H

. The blades are replaceable.

(i)

(ii)

Insert the knife blade into the sealant.

Pull the knife along and cut out the old sealant.

Note:

There are other tools available to cut out the old sealant. For example, there is a long handle type craft knife to give extended reach. Refer to

Service Tools

, for details of this and any other tools.

4 a

Laminated glass — lift out the broken pane using glass lifters (see

Service Tools

).

b

Toughened glass — remove the cut off sealant and all remaining particles of shattered glass.

5

If necessary, trim off the remaining old sealant to leave approximately 1 to 2 mm on the upright face of the cab frame aperture, as shown at

J

.

6

Apply a coat of ‘Black Primer 206J’ to the paintwork if:

a

Paintwork was damaged or scratched during the glass/sealant removal procedures.

b

The old sealant was inadvertently cut back to the cab frame during the glass/sealant removal procedures.

Preparing the Cab Frame Aperture

1

If damp or wet, dry the aperture area using a hot air gun

(sourced locally).

2

Use ‘Active Wipe 205’ to thoroughly clean and ‘prime’ the trimmed sealant. Use a lint free cloth to apply the

‘Active Wipe 205’, allow 5 minutes flash off (drying) time.

Note:

Do not use any other type of cleaning fluids, otherwise they may be absorbed into the old sealant and ultimately prevent the new glass from bonding.

F

H

J

G

S189890

S186370

S189900

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section B

21 — 4

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

21 — 4

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.

BF 1-8

1

Make sure that the new glass correctly fits the frame aperture

K

.

a

Put two spacer blocks

L

onto the bottom part of the frame aperture.

b

Install the new glass on the spacer blocks — ALWAYS

USE GLASS LIFTERS M (see

Service Tools

). Check that there is an equal sized gap all round the edge of the glass.

Note:

The spacer blocks are rectangular in section to give two common gap widths. If necessary they can be trimmed to a smaller size to give an equal sized gap around the glass.

IMPORTANT:

The glass edges MUST NOT touch the frame, otherwise movement of the frame will chip and eventually break the newly installed glass.

2

After checking for size, remove the new glass and place it on a purpose made glass stand

N

(see

Service

Tools

).

Small panes of glass will need locating on a 600 x 700 mm x

15 to 19 mm thick plywood board

P

(sourced locally to fit the glass stand

N

). It is recommended that an access hole is cut in the board to accommodate the glass lifter, making it easier and safer to handle small panes of glass. The board should be covered with felt or carpet to give an anti-scratch surface. Resting the glass on four spacer blocks will ensure clearance of the cartridge nozzle tip during application of the polyurethane sealant.

3

Make sure the glass is positioned on the stand the correct way up (i.e. with the black ceramic ink band upwards) ready for application of primer etc.

4 a

Use ‘ Active Wipe 205’ to thoroughly clean and

‘ prime’ the black ceramic ink band printed on the glass (see Note 1). Use a lint free cloth to apply the

‘Active Wipe 205’, allow 5 minutes flash off (drying) time.

Note 1

: Do not touch the glass after cleaning with the

‘Active Wipe 205’.

b

If the glass does not have a black ceramic ink band, paint a band on the glass using ‘Black Primer 206J’.

The band should be approximately 25mm (1in) wide, and the edge should be a neat straight line as shown at

R

.

K

N

P

R

L

M

S189910

S186280

S186291

S189920

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

21 — 5

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

21 — 5

Direct Glazing (cont’d)

Preparing the New Glass (cont’d)

5

Install the Ultra Fast Adhesive cartridge (see

Sealing and Retaining Compounds

and Note 2 below) into a suitable applicator gun:

a

Remove the aluminium disc cover from the base of the cartridge and discard the ‘dessicant capsule’.

b

Make sure that the rolled edge of the cartridge is not damaged — if necessary, the edges should be pressed flat, otherwise it will be difficult to remove the cartridge from the applicator gun.

c

Pierce the front ‘nozzle’ end of the cartridge to its maximum diameter.

d

Fit the pre-cut nozzle shown at

S

.

e

Install the cartridge in the applicator gun.

Note 2:

Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven (see

Service Tools

) for 1 hour to a temperature of 80°C (176°F).

Pre-heating the cartridges makes the adhesive more workable and also brings the ‘ curing’ time down to 30 minutes.

6

Apply the pre-heated adhesive to the glass (do not start in a corner). Keep the nozzle guide

T

against the edge of the glass and make sure that the adhesive forms a continuous ‘pyramid’ shape.

Note 3:

Once the pre-heated adhesive has been applied to the glass, install the glass in the aperture as soon as possible. After approximately 10 minutes the sealant will form a ‘skin’, this will prevent the glass from bonding.

7

After applying the adhesive, leave a small amount of sealant protruding from the nozzle. This will prevent any adhesive left in the cartridge from ‘curing’.

Installing the New Glass

1

Make sure the two spacer blocks are in position (see step 1 of

Preparing the New Glass

).

2

Install the glass in the frame aperture:

a

ALWAYS use the special lifting tools when moving the glass. Use a lifting strap to hold large panes of glass in position as shown

W

.

b

Sit the bottom edge of the glass on the spacer blocks as shown

X

.

c

Make sure that the glass is correctly positioned, then gently press around the edges of the glass and ensure full adhesive contact is achieved. Do not press too hard or too much adhesive will squeeze out.

S

W

Typical m/c installation

X

10-15mm

8-10mm

T

T

A186410

S189930

S186440

S189910

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

21 — 6

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

21 — 6

Direct Glazing (cont’d)

Installing the New Glass (cont’d)

3

Make the inside seal smooth:

a

Wearing surgical gloves, dip your finger in a soapy water solution.

b

Use your finger to make the inside seal smooth.

4

All exposed edges must be sealed using Black

Polyurethane Sealant (see

Sealing and Retaining

Compounds

).

5

Clean the glass after installation:

IMPORTANT:

Use extreme caution when wiping the inside of the new glass — pushing too hard on the inside of the glass will affect the integrity of the bonded seal.

a

Small amounts of sealant can be cleaned from the glass using the ‘Active Wipe 205’.

b

Large amounts of excess sealant should be left to

‘ cure’ (see Note 4) and then cut off with a sharp knife.

Note 4:

On completion of the glass replacement procedures, the sealant ‘curing’ time is 30 minutes. This means that the machine can be driven and used after 30 minutes, but it

MUST NOT be used during the curing period of 30 minutes.

c

Clean the glass using a purpose made glass cleaner.

6

On completion of the glass installation procedures tidy the work area:

a

Remove ALL broken glass from the cab area.

b

Remove the protective covers from the cab seat and control pedestals.

c

Renew all ‘warning’ and ‘information’ decals so that the new installation conforms with the original cab installation.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

22 — 1

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

22 — 1

Cab ROPS/FOPS Structure — Checks

!

WARNING

The machine is fitted with a Roll Over Protection

Structure (ROPS) and a Falling Objects Protection

Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing

ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. M odifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.

INT-2-1-9/3

Failure to take these precautions could result in death or injury to the operator.

Check the structure for damage. Check that the mounting bolts are installed and undamaged. Check the bolt torques.

Tighten them to the correct torque if necessary.

Torque Settings

Bolts

A

205 Nm (150 lbf ft)

Bolts

B

476 Nm (352 lbf ft)

A

B

S260180

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

23 — 1 Service Procedures

Engine Panels

— Removing and Fitting

Instructions for removing and fitting the engine panels are described in the routine maintenance section, refer to

Section 3

Routine Maintenance — Engine Panels

.

Section B

23 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

24 — 1

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

24 — 1

Stabiliser Leg

Wear Pad Adjustment

Instructions for adjusting the wear pads are described in the maintenance section, refer to Section 3

Stabiliser Legs —

Wear Pad Adjustment

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

25 — 1

www.WorkshopManuals.co.uk

Body and Framework

Service Procedures

Section B

25 — 1

Extending Dipper

— Wear Pad Adjustment

The Extradig dipper wear pads are bolt-on replaceable items. They support and guide the inner dipper section during extension and retraction. The following procedures explain how to inspect, and where applicable, adjust the pads.

There is a front and rear set of pads, each set comprises top wear pads

A

and bottom wear pads

B

.

The top wear pads

A

are not adjustable and must be replaced with new pads once they have worn to their limit.

See

Inspecting the Top Wear Pads

.

The bottom wear pads

B

are adjustable and take up the wear on both the top and bottom pads. They must also be replaced with new pads once they have worn to their limit.

See

Adjusting the Bottom Wear Pads

.

New wear pads

A

and

B

must be replaced as a set and fitted by a qualified service engineer.

Inspecting the Top Wear Pads

1

Park the machine on level ground. Engage the parking brake and put the transmission in neutral.

2

Position the boom and dipper as shown at

C

. Retract the Extradig dipper

D

. Make sure that the bucket is clear of the ground and the dipper is supported.

3

Stop the engine and remove the starter key.

Renew the pads when, or before they are worn down to the depth of the recess/chamfer as shown at

E

. If the pads are worn near to their limit then inspect them more frequently than recommended in the Service Schedules. To avoid damage to the dipper or wear pad make sure the pads are fitted the correct way round as shown at

J

.

Torque Settings

Item

F

Nm

56 kgf m

5.7

lbf ft

4

F

A

E

B

B

A

J

D

C

9803/3280

Purchased from www.WorkshopManuals.co.uk

S312991

Issue 1

Section B

25 — 2

www.WorkshopManuals.co.uk

Body and Framework

Service Procedures

Section B

25 — 2

Extending Dipper

— Wear Pad Adjustment (Cont’d)

Adjusting the Bottom Wear Pads

1

Park the machine on level ground. Engage the parking brake and put the transmission in neutral.

2

Support the boom and dipper as shown at

C

.

3

Stop the engine.

4

Clean the sliding faces of the inner dipper with a suitable solvent.

5

Start the engine. Retract the Extradig dipper

D

. Make sure that the bucket is clear of the ground and the dipper is supported.

6

Stop the engine.

7

With grease, mud etc. removed from the sliding faces visually check the gap between inner dipper and top wear pad

A

, as shown at

G

. The gap should be no greater than 1.5 mm (

1

/

16 in).

If the gap is greater than

1

/

16 in (1.5 mm) then adjust as follows:

a

Remove one adjusting bolt

H

and discard one washer

J

.

b

Refit and tighten bolt

H

.

c

Repeat the procedure for the remaining 3 adjusting bolts

H

on the same side of the dipper.

d

Visually re-check the gap is no greater than 1.5 mm

(1/16 in) as shown at

G

, if necessary repeat steps

a

to

c

for the other 4 bolts

H

on the opposite side of the dipper.

e

Make sure that the inner dipper seats central to the sides of the outer dipper.

Note:

Remember to alternate sides each time an adjustment is made.

Note:

When all the adjusting washers

J

have been removed and the clearance is greater than 1.5 mm ( 1 /

16 in), then wear pads

A

and

B

must be replaced as a set and fitted by a qualified service engineer.

When the adjustments have been completed, apply Waxoyl to the runners of the inner dipper.

G

A A

J

G

S148121

9803/3280

D

H

C

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

26 — 1

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

26 — 1

Sideshift

— Hydraclamp Clearance Setting

If the kingpost clearance

D

is not set correctly leaks may occur or the seal could become dislodged, use the procedure below to set the clearance.

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

2

Select the carriage clamps to lock.

3

Measure all four clamps clearance, all measurements should be taken on the centre line

A

to allow for twisting of the clamp pot as shown at

B

and

C

:

Manual

Power Sideshift

3 — 5 mm (0.11 — 0.19 in)

3 — 5 mm (0.11 — 0.19 in)

4

Release the clamps and tighten/loosen nut

1

as required, recheck measurement. When correct bend tab to lock nut.

D

A

B

D

C

D

338630

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

26 — 2

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

26 — 2

Power Sideshift — Wear Pad Renewal

Inspection

(1000 hours)

When the wear pads are worn to 6 mm (0.23 in) or below they should be replaced.

It is permissible to rotate the top wear pads 180° to prolong service life, provided the contact surface is more than 6 mm

(0.23 in) thick.

Note

: If rotating the wear pad the grease nipples will have to be swopped over.

Dismantling

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

2

Set the carriage fully to end of travel

A

, shown in centre position for clarity.

3

Lower the bucket to take the weight off the kingpost.

4

Switch OFF the engine and remove the starter key, operate the control levers to vent residual hydraulic pressure.

5

Unlock top lock tab

B

and unscrew nut

C

.

6

Remove bolt

D

through the slot in the rail

E

.

7

Hydraulic clamp

F

and washer

G

should remain in position.

8

Remove plate

J

and wear pad

H

.

Assembly

9

Fit wear pad

H

, plate

J

and bolt

D

.

10

Fit new lock tab

B

and fit nut

C

.

11

Set the hydraclamp clearance as described in

Sideshift

— Hydraclamp Clearance Setting

.

12

Repeat procedure steps 5 to 11 for the bottom clamp.

The only difference on the bottom clamps is the wear pad is on the opposite side of the rail from the top clamp so bolt

K

need not be completely removed.

Note

: If the wear pad is trapped between the rail and carriage, lower the bucket to relieve the load on the wear pad.

13

Lift the bucket and set the carriage to the opposite end of the travel, repeat the procedure for opposite side.

14

When all clamps have been assembled recheck the hydraclamp clearance of all clamps.

B

C

F

G

H

J

D

K

E

9803/3280

A

Purchased from www.WorkshopManuals.co.uk

A326840

Issue 1

Section B

26 — 3

www.WorkshopManuals.co.uk

Body & Framework

Service Procedures

Section B

26 — 3

Power Sideshift — Chain Adjustment

The chain tension should be checked at the initial 100 hours service and every 500 hours.

Check and Adjust

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

2

Position the carriage centrally and rest the bucket on the ground, remove the starter key.

3

Check the chain tension which should be 5 to 10mm

(0.19 to 0.39in) deflection

A

at the mid point. The tension should be equal for all chains.

4

If adjustment is required, slacken locknuts

C

and adjust on nuts

B

as required, tighten locknuts

C

on completion.

5

Repeat steps 3 and 4 for the opposite pair of chains.

Note

: When there is no thread left for adjustment fit new chains.

6

Operate the carriage side to side several times and recheck the deflection.

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

2

Position the carriage centrally and rest the bucket on the ground, remove the starter key.

3

Undo and remove nuts

B

.

4

Remove split pins

D

and pin

E

.

5

Withdraw chains from the machine.

Assembly

1

Thread the chains around the pulley and secure to the carriage with pin

E

, fit new split pins

D

.

2

Connect chain adjusters, tension chains as required, see

Check and Adjust

.

D

D

E

B

C

B

C

9803/3280

A

Purchased from www.WorkshopManuals.co.uk

A326830

Issue 1

Section B

30 — 1

www.WorkshopManuals.co.uk

Body & Framework

Air Conditioning

Section B

30 — 1

R

X

S

V

T

W

Component Key:

R

A/C Controls

S

Expansion Valve

T

Re-circ Air Inlet

V

Water Valve

W

HVAC Unit

X

Bulkhead Plate

9803/3280

Purchased from www.WorkshopManuals.co.uk

A401280

Issue 1

Section B

30 — 2

www.WorkshopManuals.co.uk

Body & Framework

Air Conditioning

Section B

30 — 2

HVAC/Air Conditioning Unit

— Removal and Replacement

Note: Before removing the HVAC/Air Conditioning Unit, discharge the system. Refer to Service Procedures, Air

Conditioning — Refrigerant Charging and Discharging.

The HVAC/air conditioning unit is located in the cab beneath the right hand side console. To access the unit the side console must first be removed. With the right hand side console removed as shown it is possible to gain access to the following:

HVAC Unit Top Cover

Binary Pressure Switch

Water Valve

The HVAC unit top cover must also be removed to access the following components:

Freeze Protection Thermostat

Blower Unit

Resistor

Heat Exchangers (Heater and Evaporator)

Note:

When removing components or hoses, retain any lubricant within the component/hose and replenish the system with the same amount of clean lubricant (PAG Oil).

Removal

Removal of the HVAC unit will require the assistance of a refrigeration engineer or suitably trained person since the refrigerant needs to be drained from the system.

1

Disconnect the battery.

2

Loosen and remove the side console screws and remove the side console.

3

Remove the spring clips (8 off) securing the HVAC unit top cover and carefully remove the HVAC top cover.

!

WARNING

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system must be disconnected except by a refrigeration engineer or suitably trained person. You can be severely frostbitten or injured by escaping refrigerant

4-3-4-1/2

4

Drain the refrigerant from the unit and remove all pipe work (refrigerant and air) which will prevent the unit from being withdrawn from the machine. Check around the top of unit, rear, bottom and right side.

5

Disconnect the pipe and electrical connections adjacent to the bulkhead plate

X

.

6

Remove the screws securing the HVAC unit housing to the cab and carefully withdraw the HVAC unit.

Replacement is the reverse of the removal procedure.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

30 — 3

www.WorkshopManuals.co.uk

Body & Framework

Air Conditioning

Section B

30 — 3

R

S

T

V

X

W

9803/3280

Component Key:

R

HVAC Unit Top Cover

S

Heat Exchanger (Heater and Evaporator)

T

Expansion Valve

V

Freeze Protection Thermostat

W

Blower Unit

X

HVAC Unit Housing

A401270

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

30 — 4

www.WorkshopManuals.co.uk

Body & Framework

Air Conditioning

Section B

30 — 4

Blower Unit — Removal and Replacement

The blower

W

is located inside the HVAC/air conditioning unit and can be removed without having to remove the HVAC unit from the machine.

The only user-serviceable part is the resistor which determines the blower motor speed. Other faults, excluding wiring faults, necessitate the replacement of the blower unit complete.

Resistor replacement requires the removal of the blower unit as follows:

Removal

1

Disconnect the battery.

2

Gain access to the HVAC unit by removing the right hand side console and remove the HVAC unit top cover, refer to

HVAC/ Air Conditioning Unit — Removal and

Replacement

Steps 2 and 3.

3

Disconnect the electrical connections to the blower.

4

Remove the screws securing the blower unit to the HVAC unit housing.

5

Carefully withdraw the blower from the HVAC unit.

6

To remove the resistor, disconnect the electrical connections and unscrew the resistor.

Replacement is the reverse of the removal procedure.

Freeze Protection Thermostat

— Removal and Replacement

The Thermostat

V

monitors the external temperature of the evaporator and is located inside the HVAC/air conditionig unit.

Removal

1

Disconnect the battery.

2

Gain access to the HVAC unit by removing the right hand side console and remove the HVAC unit top cover, refer to

HVAC/ Air Conditioning Unit — Removal and

Replacement

Steps 2 and 3.

3

Unclip the sensor wire from the evaporator and gently remove the wire from between the fins.

4

Disconnect the electrical connections to the thermostat.

5

Remove the screws securing the thermostat to the HVAC unit housing.

Replacement is the reverse of the removal procedure.

Evaporator Matrix

— Removal and Replacement

Note: Before removing the Evaporator Matrix, discharge the system. Refer to Service Procedures, Air

Conditioning — Refrigerant Charging and Discharging.

The evaporator matrix

S

is located inside the HVAC/air conditioning unit and can be removed without having to remove the HVAC unit from the machine.

Remova

l

Removal of the evaporator matrix will require the assistance of a refrigeration engineer or suitably trained person since the refrigerant needs to be drained from the system.

1

Disconnect the battery.

2

Gain access to the HVAC unit by removing the right hand side console and remove the HVAC unit top cover, refer to

HVAC/Air Conditioning Unit — Removal and Replacement

Steps 2 and 3.

3

Unclip the thermostat sensor wire from the evaporator and gently remove the wire from between the fins.

!

WARNING

The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system must be disconnected except by a refrigeration engineer or suitably trained person. You can be severely frostbitten or injured by escaping refrigerant

4-3-4-1/2

4

Drain the refrigerant from the unit and remove all pipe work (refrigerant and air) which will prevent the unit from being withdrawn from the machine. Check around the top of unit, rear, bottom and right side.

5

Carefully lift the evaporator matrix complete with expansion valve

T

from the housing, bearing in mind that a certain amount of resistance will be met due to the stiction from the sealing putty.

Replacement is the reverse of the removal procedure.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

30 — 5

www.WorkshopManuals.co.uk

Body & Framework

Air Conditioning

Section B

30 — 5

R

X

S

V

T

W

Component Key:

R

A/C Controls

S

Expansion Valve

T

Re-circ Air Inlet

V

Water Valve

W

HVAC Unit

X

Bulkhead Plate

9803/3280

Purchased from www.WorkshopManuals.co.uk

A401280

Issue 1

Section B

30 — 6

www.WorkshopManuals.co.uk

Body & Framework

Air Conditioning

Section B

30 — 6

Binary Pressure Switch

— Removal and Replacement

The pressure switch is located adjacent to the expansion valve

S

on the HVAC/air conditioning unit, beneath the right hand side console.

!

WARNING

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.

BF 1-10

Removal

1

Disconnect the battery.

2

Gain access to the HVAC unit by removing the right hand side console, refer to

HVAC/ Air Conditioning

Unit — Removal and Replacement

Step 2.

3

Disconnect the electrical connections and unscrew the pressure switch.

Replacement

1

Screw the pressure switch into the pressure switch port and torque tighten sufficiently to form a gas-tight seal.

2

Run the air conditioning and check the pressure switches for leaks. If any leaks are found, tighten the pressure switch further until the leaking stops.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

35 — 1

www.WorkshopManuals.co.uk

Body & Framework

Loader Arms

Section B

35 — 1

A

T

R

U

H

S

K

L

B

Y

D

F

X

E

G

Z

9803/3280

Purchased from www.WorkshopManuals.co.uk

S265931

Issue 1

Section B

35 — 2

www.WorkshopManuals.co.uk

Body & Framework

Loader Arms

Section B

35 — 2

Removal and Replacement

Removal

1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

2

Remove loader end attachment (such as a shovel) if fitted. If the attachment is hydraulically operated, disconnect attachment hoses and plug/cap immediately. Vent residual hydraulic pressure prior to removing hoses by operating the control levers with the engine switched off.

!

WARNING

DO NOT work under raised loader arms unless they are adequately supported by stands and/or slings.

BF 3-1

3

Remove the engine panels, refer to Section 3

Routine

Maintenance — Engine Panels

.

4

Raise the loader arms to give access to the lift ram pivot pins

A

.

5

Sling the loader arms as shown at

X

. Make sure that the slings are taut and therefore holding the weight of the loader arms.

6

Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.

7

Remove the lift ram pivot pins

A

.

Note

: Care must be taken when removing the lift ram pivot pin, once the pin is removed the ram will drop. Either hold the ram using a sling or have a second person hold the ram before removing the pin.

8

Lower the loader arms to the ground using the slings, it may be necessary to retract the lift rams to enable the loader arms to rest fully on the ground. Make sure the lift rams do not foul when retracted.

9

Make sure residual hydraulic pressure has been vented.

Disconnect the shovel ram and auxiliary (if fitted) hoses, shown at

B

. Plug and cap the hoses immediately.

10

Disconnect the electrical connections (not shown) to the loader shovel reset switch (if fitted).

11

Remove pivot pin retaining bolts

D

,

E

,

F

and

G

.

12

Sling the loader arms as shown at

Y

. Make sure that the sling is wrapped around the loader arms only and not the level links.

13

Remove klipring

H

and shim

K

.

!

WARNING

The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a ‘scissor’ point with the loader arm. Make sure the interlevers are securely blocked when working in the loader arm area.

BF 2-1

14

Secure the interlever lever linkage as shown at

Z

, otherwise with level link pivot pin

L

removed, the interlever linkage could pivot about its centre and cause injury and/or damage.

15

Remove pivot pin

L

(use slide hammer kit, service tool

993/68100).

16

Repeat steps

13

to

15

for the opposite level link pivot pin.

17

Remove bolt

T

and retaining ring

R

.

18

Remove pivot pin

U

(use slide hammer kit, service tool

993/68100)

19

Repeat steps

17

and

18

for the opposite loader arm pivot pin.

20

When all four pivot pins have been removed, carefully reverse the machine clear of the loader arms

Replacement

Replacement is a reversal of the removal sequence.

Fit pivot pins with the extraction hole on the outside of the machine.

Check operation of loader shovel reset switch (if fitted).

Apply grease to all mainframe bores.

Apply rust inhibiting oil to all pivot pins.

If fitting new liner bearings, assemble with a close fitting shouldered mandrel to ensure minimum ovality.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

36 — 1

www.WorkshopManuals.co.uk

Body & Framework

Stabiliser Legs

Section B

36 — 1

G

F

9803/3280

D

C

A B

E

S261790

Purchased from www.WorkshopManuals.co.uk

S216810

Issue 1

Section B

36 — 2

www.WorkshopManuals.co.uk

Body & Framework

Stabiliser Legs

Section B

36 — 2

Removal and Replacement

— (Centremount Machines)

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and stop the engine.

2

Lower the stabiliser legs to the ground.

DANGER

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

3

Make sure the engine is switched off, vent residual hydraulic pressure by moving the backhoe and stabiliser control levers back and forth.

Note:

If a check valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

4

Remove the stabiliser ram:

a

Carefully disconnect hydraulic hoses

A

and

B

from the stabiliser hydraulic ram, label the hoses before removing (as an aid to assembly). Release the connections slowly.

b

If a stabiliser foot is fitted, remove nut

C

and retaining bolt

D

. Drive out the foot retaining pin

E

.

!

CAUTION

The ram is heavy. It is recommended that the ram is removed with the assistance of a sling and suitable lifting appliance.

BF 2-4

c

Wrap a suitable sling around the stabiliser ram, make sure that the weight of the ram is supported by the sling.

d

Remove the ram pivot pin retaining nut and bolt, drive out the ram pivot pin as shown at

F

.

e

Remove the stabiliser ram.

5

Remove the stabiliser leg:

!

CAUTION

The stabiliser leg is heavy. It is recommended that the stabiliser leg is removed with the assistance of a sling and suitable lifting appliance.

BF 2-6

a

Wrap a suitable sling around the stabiliser leg, make sure that the weight of the leg is supported by the sling.

b

Remove the stabiliser leg pivot pin retaining nut and bolt, drive out the stabiliser leg pivot pin

,

as shown at

G

.

c

Remove the stabiliser leg.

Replacement

Replacement is a reversal of the removal sequence.

Use suitable lifting appliances to locate the stabiliser ram and the stabiliser leg.

After replacing or fitting the stabiliser leg, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

36 — 3

www.WorkshopManuals.co.uk

Body & Framework

Stabiliser Legs

Section B

36 — 3

A

9803/3280

C

B

Purchased from www.WorkshopManuals.co.uk

S271850

Issue 1

Section B

36 — 4

www.WorkshopManuals.co.uk

Body & Framework

Stabiliser Legs

Section B

36 — 4

Removal and Replacement

— (Sideshift Machines)

Removal

1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

2

Lower the loader shovel to the ground.

3

Make sure that the backhoe assembly is set central to the mainframe as shown. If necessary ‘ sideshift’ the backhoe into a central position.

4

Remove the stabiliser foot and ram, refer to Section E

Hydraulic Rams, Removal and Replacement —

Stabiliser Ram

.

5

Remove the inner leg:

a

Locate a suitable jack underneath the inner leg.

b

Use the jack to lift the inner leg until the top wear pads

A

protrude from the top of the outer leg section.

c

Remove the wear pads and attach suitable lifting gear through the wear pad locating holes.

d

Use suitable lifting equipment, lift the inner leg clear.

Replacement

Replacement is a reversal of the removal sequence.

Select suitable size upper pads

A

to achieve a maximum permissible float of 1mm (0.039 in.).

Make sure that the bottom pads

C

are held in position before guiding the inner leg into position. If the lower pads are not secured then the inner leg could dislodge the pads during assembly.

When the inner leg is in position adjust the bottom pads, refer to Section 3

Stabiliser Legs — Wear Pad Adjustment

.

Apply a grease such as JCB slew grease (part number

4003/1601) to the threads of pad

B

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

37 — 1

www.WorkshopManuals.co.uk

Body & Framework

Kingpost

Section B

37 — 1

Removal and Replacement

72 m 14

71 om Pivot Bearing — 15ft 6in / 17ft Backhoe)

A261800

Item 14

(Boom Pivot Bearing — 14ft Backhoe)

A252870

Item 15

57

(Kingpost Pivot Bearing)

A252880

7

8

9

10

17

15

17

5

6

9803/3280

12

16

3A

14

4

6

13

17

2

15

14

16

17

13

1

3A

3

Purchased from www.WorkshopManuals.co.uk

11

S254893

Issue 1

Section B

37 — 2

www.WorkshopManuals.co.uk

Body & Framework

Kingpost

Section B

37 — 2

Removal and Replacement

Removal

1

Slew the kingpost to the centre and remove the boom and dipper.

!

WARNING

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

2

Make sure that the slew lock pivot pin

11

is in its stowage position (i.e. not fitted in the ‘slew lock’ position.

3

Working from the base up, disconnect the backhoe hydraulic hoses, before disconnecting the hoses make sure that they are labelled (to assist with reassembly).

4

Plug and cap all open hydraulic connections to prevent ingress of dirt and loss of hydraulic fluid.

5

Remove thin nuts

1

(2 off per pivot pin) and remove pivot pin retaining bolt

2

(2 off).

6

Remove the slew ram (eye end) pivot pins

3

(2 off) and bearing liners

3A

.

7

Attach suitable lifting straps to the kingpost assembly.

Note that the weight of the kingpost casting is approximately 130 kg (287 lbs).

8

Remove the boom lock assembly (see Boom Lock

Removal and Replacement in Controls, section D).

9

Remove thin nuts

4

(2 off) and remove retaining bolt

5

.

10

Remove the kingpost top pivot pin

6

.

11

Remove bolt

7

, washer

8

, and spacer

9

.

12

Remove the kingpost bottom pivot pin

10

.

13

Remove the kingpost casting

12

from the rear frame and thrust washers

13

.

Inspection

Inspect the nickel bronze liner bearings

14

and

15

for signs of damage, wear, scores or nicks etc. Use a suitable mandrel (manufactured locally) to facilitate removal of the liner bearings.

To ensure the drift is manufactured to the correct size, the liner bearing dimensions are shown on the illustration. Note that the dimensions are NOMINAL figures only and must not be used to manufacture the liner bearings.

Replacement

Replacement is generally a reversal of the removal procedures, however note the following:

To assist with the identification of 15ft 6in and 17ft centremount kingposts the number

6 is stamped on the kingpost to identify 60mm diameter bores.

Check for and remove any burrs and sharp edges on both housing bore, bearing and pivot pin to minimise assembly damage.

If necessary, use oil or suitable lubricant to facilitate pressing-in bearing — to minimise scoring of mating face.

Bearings

14

and

15

have ‘lead-in’ diameters (noticeable with a slight step), always install the smaller diameter first into the pivot bore.

Thrust washers

13

come in different sizes to allow for variations of castings.

Make sure that the boom base liner bearings

14

are fully engaged in the boom base pivot bores. There must be a recess of 5mm (3/16 inch) to allow for installation of the seals

16

.

If fitting new liner bearings, assemble with a close fitting shouldered mandrel. Refer to liner bearing sizes on the illustration (nominal figures given).

Make sure that the liner bearings

15

are fully engaged in the kingpost pivot bores. There must be a recess of 6mm (1/4 inch) to allow for installation of the seals

17

.

If a new kingpost casting has been installed, the boom lock may need resetting, refer to the boom lock removal and replacement procedures.

Seals

16

and

17

are lip seals, on reassembly make sure that the seal lips face outward (shown in insets on the kingpost pivot).

Make sure that thin lock nuts, items

1

and

4

are ‘just’ free when locked into position.

Make sure that all pivot bores and pivot pins are clean and greased when assembling. When fully assembled, apply grease at each grease nipple before operating the machine.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section B

38 — 1

www.WorkshopManuals.co.uk

Body & Framework

Boom and Dipper

Section B

38 — 1

E

B

F

G

J

H

L

A

C

D

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

38 — 2

www.WorkshopManuals.co.uk

Body & Framework

Boom and Dipper

Section B

38 — 2

Boom — Removal and Replacement

Removal

The procedures describe the removal of the boom with the boom and dipper rams still installed. If required, these items can be removed separately before removing the boom, refer to the appropriate removal and replacement procedure.

1

Remove the backhoe bucket and place the backhoe in the position shown at

A

.

2

Lower the stabilisers.

3

Stop the engine and disconnect the battery (to prevent the engine being started).

4

Operate the backhoe control levers back and forth several times to release pressure trapped in the hydraulic hoses.

!

DANGER

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

5

Disconnect the hydraulic hoses from the bulkhead plate

B

. Always label hydraulic hoses before disconnecting them, this will ensure that they are correctly reconnected. Plug and cap all hose open ends to prevent ingress of dirt and loss of hydraulic fluid.

6

Remove the dipper, see

Dipper — Removal and

Replacement.

7

Wrap a sling around the boom as shown at

D

. Make sure the weight of the boom is held by the sling before removing pivot pins etc.

8

Place a suitable support underneath the boom ram

C

.

9

Remove two thin nuts

E

, bolt

F

and pivot pin

G

.

10

Remove heavy duty circlip

H

, spacers

J

(one fitted each side) and pivot pin

L

. Mark the spacers so that they can be replaced in the same positions.

11

Hoist the boom clear of the kingpost assembly.

Replacement

!

WARNING

Hydraulic Fluid

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.

INT-3-1-10/1

Replacement is generally a reversal of the installation procedure.

The boom pivot pin

G

must be retained using two M12 thin nuts. Fit the first thin nut with zero torque, fit the second thin nut and torque to 98Nm (72 lbf ft).

When fitting the boom to the kingpost assembly, make sure that spacers

J

are refitted in their original positions.

Replace all pivot pin seals as required.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

38 — 3

www.WorkshopManuals.co.uk

Body & Framework

Boom and Dipper

Section B

38 — 3

G

F

E

K

J

H

B

C

A

D

9803/3280

L

S266170

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

38 — 4

www.WorkshopManuals.co.uk

Body & Framework

Boom and Dipper

Section B

38 — 4

Dipper — Removal and Replacement

Removal

The procedures describe the removal of the dipper with the extradig (if fitted) and the bucket ram still installed. If required, these items can be removed separately before removing the dipper, refer to the appropriate removal and replacement procedure.

1

Remove the backhoe bucket and place the backhoe in the position shown at

A

.

2

Lower the stabilisers.

3

Stop the engine and disconnect the battery (to prevent the engine being started).

4

Operate the backhoe control levers back and forth several times to release pressure trapped in the hydraulic hoses.

!

DANGER

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

Replacement

!

WARNING

Hydraulic Fluid

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.

INT-3-1-10/1

Replacement is generally a reversal of the installation procedure.

The boom to dipper pivot pin

K

must be retained using two

M12 thin nuts. Fit the first thin nut with zero torque, fit the second thin nut and torque to 98Nm (72 lbf ft).

When fitting the dipper to the boom, make sure that shim, item

L

is installed as shown.

Replace all pivot pin seals as required.

5

Disconnect the hydraulic hoses, as shown at

B

. Always label hydraulic hoses before disconnecting them, this will ensure that they are correctly reconnected. Plug and cap all hose open ends to prevent ingress of dirt and loss of hydraulic fluid.

6

Place a suitable support underneath the dipper ram as shown at

C

.

7

Wrap a sling around the dipper as shown at

D

. Make sure the weight of the dipper is held by the sling before removing pivot pins etc.

8

Remove nut

E

, bolt

F

and pivot pin

G

.

9

Remove two thin nuts

H

, bolt

J

and pivot pin

K

.

Note:

It is important to use two thin nuts, this arrangement allows the pivot pin retaining bolt to be secured without inducing a lateral tension.

10

Hoist the dipper clear of the boom.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section B

39 — 1

www.WorkshopManuals.co.uk

Body & Framework

Hydraulic Tank

Section B

39 — 1

Removal and Replacement

Removal

!

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.

Replacement

Replace the tank by reversing the removal procedure.

If a new tank is being fitted, remove the tool box from the old tank and fit to the new tank.

Apply JCB Threadlocker and Sealer to drain plug

B

.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-2

* When refitting the suction hose

G

make sure it is correctly fitted and phased on the tank spigot. There must be at least

12 mm (0.5 in) clearance between the hose and the gearbox casing. Phase the 2 clips

F

180 o apart.

1

Operate the control levers to vent residual pressure.

2

Remove the filler cap and unscrew plug

B

to drain the tank.

Refill with clean hydraulic oil as specified, refer to Section 3

Fluids, Lubricants, Capacities and Specifications

.

*

3

Disconnect and plug the hydraulic hoses

D

from the rear of the tank.

*

Operate the machine until the hydraulic oil reaches operating temperature (50 o

C, 122 o

F). Stop the engine and check for leaks.

*

Note:

Some machine variants may have different return hose configurations at the tank to those illustrated. Be sure to disconnect all hoses.

Torque Setting

4

Loosen the 2 clips hose at the tank.

F

on the suction hose

G

. Pull off the

*

Item

B

F

Nm

100

5 lbf ft kgf m

73.76

10.20

4 0.5

5

Support the tank, then unscrew mounting bolts

E

and lift tank away from the machine.

E

E

E

E

B

D

G

D

F

F

A401540

9803/3280

Purchased from www.WorkshopManuals.co.uk

D

Issue 2*

Section B

40 — 1

www.WorkshopManuals.co.uk

Body & Framework

Power Sideshift Ram

Section B

40 — 1

Removal and Replacement

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground.

2

Position the carriage in the central protruding travel position at 150 mm (6 in) from end of the rail, rest the bucket on the ground and remove the starter key.

3

Operate control levers to vent hydraulic pressure.

4

Disconnect hydraulic hoses

A

and plug.

5

Disconnect all four chains at adjusters

B

and disengage chains from ram pulleys.

6

Remove pin

C

from one end and support the ram.

7

Remove pin

C

from opposite end, withdraw ram.

Replacement

1

Locate the ram at one end with pin

C

. Adjust the ram eye end so the the opposite end of the ram aligns with mounting bracket.

2

Secure the opposite end of the ram in position with pin

C

.

3

With a spanner on the rod end flats

D

adjust the rod so that the ram eye end engagement is equal at each end of the ram. Lock eye ends in position with nut

E

.

4

Reconnect the hydraulic hoses.

5

Locate the chains around the applicable ram pulleys.

Reconnect chains and adjust as required, refer to

Service Procedures, Power Sideshift — Chain

Adjustment

.

C

E D

B

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

A326850

Issue 1

Section B

50 — 1

www.WorkshopManuals.co.uk

Body and Framework

Cab Panels

Section B

50 — 1

Removal and Replacement

Side Console

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Disconnect the battery.

3

Working in the cab, remove the fixing

A

at the top of the instrument panel and carefully lift the panel forward to reveal the connections at the back as shown.

4

Disconnect the electrical connectors and heater controls cables at the rear of the instrument panel, then remove the instrument panel assembly clear of the side console. Label the connectors and controls cables before disconnecting to ensure correct replacement.

5

Remove the hand throttle lever knob

B

, remove the screws

C

from the hand throttle lever and mounting bracket assembly

D

inside the side console as shown.

Withdraw the handle through the slot in the panel.

6

Remove the screws from around the base of the stabiliser control levers

E

, carefully withdraw the lever assembly from the side console and disconnect the control cables from the underside. Label each control cable before disconnecting to ensure correct replacement.

7

Unscrew the knob and lock nut from the boom lock control

F

.

8

Remove the fixings

G

(5 off) securing the side console panel at positions shown. Carefully lift up the rear corner of the side panel over the boom lock control outer sleeve, and then lift the side panel clear.

Replacement

Replacement is the reverse of the removal sequence.

Take care when removing/replacing the console panel to ensure that harnesses do not become snagged and that no other connections have been disturbed.

After re-fitting, operate the side console controls and check they all function correctly.

C

D

G

G

G

C

G

A

F

E

B

G

A394410

9803/3280

Purchased from www.WorkshopManuals.co.uk

A404670

Issue 1

Section B

51 — 1

www.WorkshopManuals.co.uk

Body and Framework

Cab Panels

Section B

51 — 1

Removal and Replacement

Front/Steering Console

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Disconnect the battery.

3

Working in the cab, remove the steering wheel as shown.

4

Remove the fixings

A

(4 off) at positions shown and take off the steering column pedestal cover.

5

Remove the column switches

B

.

6

Remove the instrument panel

C

.

7

Remove the fixings

D

(4 off) securing the front console panel at positions shown and then carefully lift up the front console clear of the steering column assembly.

Replacement

Replacement is the reverse of the removal sequence.

Take care when removing/replacing the console panel to ensure that harnesses do not become snagged and that no other connections have been disturbed.

After re-fitting, operate the front/steering console controls and check they all function correctly.

B

A

C

A

A

A

B

D

D

9803/3280

D

Purchased from www.WorkshopManuals.co.uk

D

A396920

Issue 1

i

Section C

www.WorkshopManuals.co.uk

Electrics

Section C i

Contents

Service Tools

Technical Data

System Type

Battery

Alternator

Fuses & Relays

Fuse Link Box

Relays

*

*

Basic System Operation

Circuit Schematics

Basic Machine — 3CX, 4CX, 214, 215, 217 (Not 214e)

Synchro Shuttle and Powershift

*

Options

— Steer Mode (4x4x4)

— 2 Wheel Steer/Brake Mode

— 2 Wheel Steer/Brake Mode (Germany)

— All Wheel Steer/Brake Mode

— Auxiliary and Hydraclamp Hydraulics

— Speedometer

— Hand Held Tools

— Dedicated Quickhitch

— Pole Planter

— Smooth Ride System (SRS)

— Return to Dig (Shovel Reset)

— Hydraulic Speed Control (HSC)

6 Speed Powershift (Shiftmaster)

214e Machines

Service Procedures

Electrical Testing Methods

Using a Multimeter

— Measuring DC Voltage

— Measuring Resistance

— Measuring Continuity

— Testing a Diode

Battery

Maintenance

Safety

Testing

Specific Gravity Testing

Alternator

Charging Test

Starter Motor

Starting Circuit Test

Wiring Harness

Repair Procedure

Page No.

1 — 1

19 — 1

19 — 3

19 — 3

19 — 3

19 — 5

20 — 1

20 — 1

20 — 2

20 — 2

21 — 1

22 — 1

23 — 1

2 — 1

2 — 1

2 — 1

2 — 2

2 — 3

2 — 3

4 — 1

4 — 5

4 — 7

4 — 7

4 — 7

4 — 9

*

4 — 9

4 — 9

4 — 11

4 — 11

4 — 11

4 — 11

4 — 11

4 — 11

4 — 13

4 — 15

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

ii

Section C

www.WorkshopManuals.co.uk

Electrics

Section C ii

Page No.

Contents

Alternator

Removal and Replacement

Starter Motor

Removal and Replacement

Inspection

Dismantling and Assembly

Earth Points

Harness Data

Drawings

*

Harness Interconnection

30 — 1

40 — 2

40 — 2

40 — 2

145 — 1

150 — 1

150 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section C

1 — 1

www.WorkshopManuals.co.uk

Electrics

Service Tools

Section C

1 — 1

S188231

AVO Test Kit

1 892/00283

2 892/00298

3 892/00286

4 892/00284

5 892/00282

6 892/00285

Tool Kit Case

Fluke Meter 85

Surface Temperature Probe

Venture Microtach Digital

Tachometer

100 amp Shunt — open type

Hydraulic Temperature Probe

993/85700 Battery Tester

892/00882 Socket for Alternator Pulley Nut

825/00410

825/99833

15 mm Crowfoot Wrench

Adapter

S239510 S216770

9803/3280

S216200

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

2 — 1

www.WorkshopManuals.co.uk

Electrics

Technical Data

Section C

2 — 1

General Electrical Data

System Type

Battery (Heavy Duty)

— Cold crank amps for 1 minute to

1.4 volts per cell at -18 deg C (0 deg F)

— Reserve capacity (minutes) for 25 amp load

Battery (Temperate)

— Cold crank amps for 1 minute to

1.4 volts per cell at -18 deg C (0 deg F)

— Reserve capacity (minutes) for 25 amp load

Alternator

2WS

4WS

4WS (air conditioning or ServoPlus builds)

12 Volt, negative earth

550

220

410

170

65 Amp nominal output

72 Amp nominal output

85 Amp nominal output

Max load

50

Output amps

45

40

60

55

70

65

90

85

80

75

25

20

35

30

15

10

5

0

0 500 1000 1500 2000 2500

Engine speed rpm

3000

85A

65A

72A

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

2 — 2

www.WorkshopManuals.co.uk

Electrics

Technical Data

Section C

2 — 2

Fuses and Relays

Fuses

!

CAUTION

Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

8-3-3-5

The relays and fuses are located in the side console underneath cover

A

.

If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A,

B and C) and row numbers (1 to 10). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

4

3

6

5

2

1

10

9

8

7

C

7

6

5

10

9

8

2

1

4

3

B

7

6

5

10

9

8

2

1

4

3

A

396500

A

Machines up to serial no. 933756

COLUMN ‘A’

1

Hydraulic auxiliary

2

Fuel pump solenoid (engine stop)

3

Direction indicators

4

Steer mode proximity switch

5

Gearbox control, Transmission

6

Spare

7

Brake lights

8

4 wheel drive (automatic brakes)

9

Left hand side lights

10

Right hand side lights

COLUMN ‘B’

1

Instruments, Buzzer

2

Front horn, Front washer/wiper

3

Rear horn

4

Heated seat, Cigar lighter, Face level fan

5

Rear wiper/wash

6

Brake switch

7

Return to dig enable

8

Rear working lights

9

Headlights

10

Front working lights

COLUMN ‘C’

1

Lights

2

Hazard light

3

Beacon, Interior light

4

Radio

5

Thermostart

6

Heater

7

Ignition relay coils

8

Main beam

9

Fog light

10

Dip beam

Fuse Rating

10 Amp

5 amp

7.5 amp

7.5 Amp

10 Amp

5 Amp

3 Amp

5 Amp

5 Amp

5 Amp

15 Amp

7.5 Amp

15 Amp

10 Amp

10 Amp

5 Amp

25 Amp

20 Amp

25 Amp

7.5 Amp

15 Amp

10 Amp

5 Amp

20 Amp

30 Amp

3 Amp

15 Amp

3 Amp

15 Amp

9803/3280

396490

*

Machines from serial no. 933757

COLUMN ‘A’

1

Hydraulic auxiliary

2

Fuel pump solenoid (engine stop)

3

Direction indicators

4

Steer mode proximity switch

5

Transmission

6

Gear select / Forward Reverse

7

Transmission

8

Brake lights

9

Left hand side lights

10

Right hand side lights

COLUMN ‘B’

1

Instruments, Buzzer

2

Front horn, Front washer/wiper

3

Rear horn

4

Heated seat, Cigar lighter, Face level fan

5

Rear wiper/wash

6

Brake switch

7

Return to dig enable

8

Rear working lights

9

Headlights

10

Front working lights

COLUMN ‘C’

1

Lights

2

Hazard light

3

Beacon, Interior light

4

Radio

5

Thermostart

6

Heater

7

Ignition relay coils

8

Main beam

9

Fog light

10

Dip beam

Fuse Rating

10 Amp

5 amp

7.5 amp

7.5 Amp

10 Amp

3 Amp

10 Amp

7.5 Amp

5 Amp

5 Amp

5 Amp

15 Amp

7.5 Amp

15 Amp

10 Amp

10 Amp

5 Amp

25 Amp

20 Amp

25 Amp

7.5 Amp

15 Amp

10 Amp

5 Amp

20 Amp

30 Amp

3 Amp

15 Amp

3 Amp

15 Amp

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section C

2 — 2

www.WorkshopManuals.co.uk

Electrics

Technical Data

Section C

2 — 2

Fuses and Relays

Fuses

!

CAUTION

Always replace fuses with ones of correct ampere rating to avoid electrical system damage.

8-3-3-5

The relays and fuses are located in the side console underneath cover

A

.

If a fuse melts, find out why and rectify the fault before fitting a new one. The fuses are identified using column letters (A,

B and C) and row numbers (1 to 10). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown.

4

3

6

5

2

1

10

9

8

7

C

7

6

5

10

9

8

2

1

4

3

B

7

6

5

10

9

8

2

1

4

3

A

396500

A

Machines up to serial no. 933756

COLUMN ‘A’

1

Hydraulic auxiliary

2

Fuel pump solenoid (engine stop)

3

Direction indicators

4

Steer mode proximity switch

5

Gearbox control, Transmission

6

Spare

7

Brake lights

8

4 wheel drive (automatic brakes)

9

Left hand side lights

10

Right hand side lights

COLUMN ‘B’

1

Instruments, Buzzer

2

Front horn, Front washer/wiper

3

Rear horn

4

Heated seat, Cigar lighter, Face level fan

5

Rear wiper/wash

6

Brake switch

7

Return to dig enable

8

Rear working lights

9

Headlights

10

Front working lights

COLUMN ‘C’

1

Lights

2

Hazard light

3

Beacon, Interior light

4

Radio

5

Thermostart

6

Heater

7

Ignition relay coils

8

Main beam

9

Fog light

10

Dip beam

Fuse Rating

10 Amp

5 amp

7.5 amp

7.5 Amp

10 Amp

5 Amp

3 Amp

5 Amp

5 Amp

5 Amp

15 Amp

7.5 Amp

15 Amp

10 Amp

10 Amp

5 Amp

25 Amp

20 Amp

25 Amp

7.5 Amp

15 Amp

10 Amp

5 Amp

20 Amp

30 Amp

3 Amp

15 Amp

3 Amp

15 Amp

9803/3280

396490

*

Machines from serial no. 933757

COLUMN ‘A’

1

Hydraulic auxiliary

2

Fuel pump solenoid (engine stop)

3

Direction indicators

4

Steer mode proximity switch

5

Transmission ECU 1

6

Gear select / Forward Reverse

7

Transmission ECU 2

8

Brake lights

9

Left hand side lights

10

Right hand side lights

COLUMN ‘B’

1

Instruments, Buzzer

2

Front horn, Front washer/wiper

3

Rear horn

4

Heated seat, Cigar lighter, Face level fan

5

Rear wiper/wash

6

Brake switch

7

Return to dig enable

8

Rear working lights

9

Headlights

10

Front working lights

COLUMN ‘C’

1

Lights

2

Hazard light

3

Beacon, Interior light

4

Radio

5

Thermostart

6

Heater

7

Ignition relay coils

8

Main beam

9

Fog light

10

Dip beam

Fuse Rating

10 Amp

5 amp

7.5 amp

7.5 Amp

10 Amp

3 Amp

10 Amp

7.5 Amp

5 Amp

5 Amp

5 Amp

15 Amp

7.5 Amp

15 Amp

10 Amp

10 Amp

5 Amp

25 Amp

20 Amp

25 Amp

7.5 Amp

15 Amp

10 Amp

5 Amp

20 Amp

30 Amp

3 Amp

15 Amp

3 Amp

15 Amp

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

2 — 3

Fuses and Relays

(continued)

Link Box Fuses

To further protect the machine wiring harnesses and electrical circuits, a fuse link box is fitted to the battery, as shown at

B

. Remember to check the main circuit fuses as well as the link box fuses shown on this page.

1

Hazard warning lights, Beacon, Lights

2

Wash/Wipe, Transmission, Indicators

3

Work lights, Fog Lights, Brake lights

4

Ignition, Heater, Thermostart

30 Amp

50 Amp

50 Amp

50 Amp

Electrics

Technical Data

1

3

2

4

B www.WorkshopManuals.co.uk

Relays

4 speed Powershift / Synchro Shuttle

The relays listed below are located in the side console underneath cover

A

.

*

*

*

*

1

Ignition 1

2

Hammer

3

Auxiliary (jaw bucket)

4

Main lights

5

Engine run

6

Hydraulic speed control (HSC)

7

Buzzer (from serial no. 933757 only)

8

Buzzer

9

Ignition 2

10

Front working lights

11

Rear working lights

12

Direction indicator

13

Neutral start

14

Rear horn

15

Parking brake warning light

16

Air conditioning compressor

17

Parking brake (from serial no. 933757 only)

The relays listed below are located in the front console as shown at

C

.

FD1

Forward HI/LO

FD2

Forward

FE1

Reverse HI/LO

FE2

Reverse

FF1

Interlock

FF2

Drive

FG1

Blank

FG2

Transmission dump

FH1

Auto 2WD

FH2

4WB

A396480

6 speed Powershift (Shiftmaster)

The relays listed below are located in the side console underneath cover

A

.

*

1

Ignition 1

2

Hammer

3

Auxiliary (jaw bucket)

4

Main lights

5

Engine run

6

Hydraulic speed control (HSC)

7

Buzzer

8

Buzzer

9

Ignition 2

*

10

Front working lights

11

Rear working lights

12

Direction indicator

13

Neutral start

14

Rear horn

*

*

15

Parking brake warning light

16

Air conditioning compressor

17

Parking brake

The relays listed below are located in the front console as shown at

D

.

FG1

Reverse Alarm

FG2

Transmission dump

FH1

2WB

FH2

Brake lights

Note:

Relay base positions may vary from those shown at

D

.

Compare wire numbers on the relevant front consloe harness drawing to confirm relay identification

Section C

2 — 3

$

%

^

&

4

3

6

5

2

1

10

9

8

7

C

7

6

5

10

9

8

2

1

4

3

B

7

6

5

10

9

8

2

1

4

3

A

@ 8

1

£

9

0

!

2

3

4

5

6

7

396500

C

D

A405390

A405400

Issue 3*

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 1

Circuit Schematic — Basic Machine

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 1

1

2

6

3

7

4

8

W

8

2 4

6

5

810

A

001

412

407

9 11

16

10

B

15

5

2

14

3

1

20

21

22

23

24

19

17

8

830

5 17 2

18

25

26 27 28

51 52 53 54 55

56

LH

SPEAKER

57

RH

SPEAKER

601

860

859

602

805

29

30

32 33 34 35 36 37 38 39

31

SIDE CONSOLE

INSTRUMENTS

830

420

40

7 2

5 1

411

42

FRONT CONSOLE

INSTRUMENTS

41

43 43 43 43

44 45 46 47 48 49 50

806

EARTH

835

855

861

837

58

407

401

C

D

E

F

G

H

10 18 1 3

4 2

12

6

8

4 2

13

6 8

002

200

830

J

200

007

002

133

K

L

M

N

001

A409180

852/30241sht1 Iss1

P

Q

9803/3280

Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 2

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 2

Circuit Schematic — Basic Machine

Refer to pages C/4-1 and C/4-4.

The basic circuit shows a standard machine. The remaining pages in section C/4 show machine circuits that differ from the

‘basic’. Note that ONLY the differences are shown.

*

Main Components:

1 Thermostart

2 Battery Isolator

3 Battery

4 Starter Switch

5 Neutral Start Relay

6 Starter Solenoid

7 Starter Motor

8 Alternator

9 Cold Start Advance Solenoid

10 Cold Start Advance Switch

11 Engine Shut-Off Solenoid (ESOS)

12 Ignition Relay ‘1’

13 Ignition Relay ‘2’

14 Rear Horn Relay

15 Rear Horn Switch

16 Rear Horn

17 Hazard Warning Switch

18 Indicator Flasher Unit

19 Direction Indicator Switch

20 LH Front Indicator

21 LH Rear Indicator

22 RH Front Indicator

23 RH Rear Indicator

24 Engine Coolant Temperature Sender

25 Fuel Gauge Sender

26 Engine Coolant Temperature Gauge

27 Fuel Gauge

28 Clock

29 Tachometer

30 Hourmeter

31 Side Instrument Console

32 Alternator Warning Indicator Light

33 Parking Brake Indicator Light

34 Engine Coolant Temperature Indicator Light

35 Transmission Oil Temperature Indicator Light

36 Engine Oil Pressure Indicator Light

37 Transmission Oil Pressure Indicator Light

38 Air Filter Blocked Indicator Light

39 Panel Illumination

40 Warning Buzzer Relay

41 Warning Buzzer

42 Front Instrument Console

43 Master Warning Lights

44 Turn Signal Indicator

45 Side Lights Indicator

46 Hazard Warning Indicator

47 Main Beam Warning Indicator Light

48 Rear Working Light Indicator

49 Front Working Light Indicator

50 Rear Fog Light Indicator

51 Engine Coolant Temperature Switch

52 Transmission Oil Temperature Switch

53 Engine Oil Pressure Switch

54 Transmission Oil Pressure Switch

55 Air Filter Restriction Switch

56 LH Speaker

57 RH Speaker

58 Radio (if fitted)

*

Connections:

A From

A

on page C/4-5 and C/4-13 as applicable

B To

B

on page C/4-5

C To

C

on page C/4-4

D From

D

on page C/4-5 and C/4-13 as applicable

E From

E

on page C/4-4

F From

F

on page C/4-4

G From

G

on page C/4-4

H From

H

on page C/4-4

J From

J

on page C/4-4

K To

K

on page C/4-4

L To

L

on page C/4-4 and C/4-8, and C/4-13 as applicable

M To

M

on page C/4-8 and C/4-13 as applicable

N To

N

on page C/4-4

P To

P

on page C/4-4

Q To

Q

on page C/4-4

9803/3280 Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 3

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 3

Circuit Schematic — Basic Machine (cont’d)

*

Main Components:

59 Cigar Lighter

60 Face Level Fan

61 Face Level Fan Switch

62 Heated Seat

63 Heated Seat Switch

64 Rear Washer/Wiper Switch

65 Rear Wiper Motor

66 Rear Washer Motor

67 Front Washer/Wiper Switch

68 Front Washer Motor

69 Front Wiper Intermittent Electronic Control Unit

70 Front Wiper Motor

71 Head Light Flasher Switch

72 Front Horn Switch

73 Front Horn

74 Rear Fog Light Switch

75 Rear Fog Light

76 Removed For Territories — Italy, Germany

77 Fitted For Territories — Italy, Germany

78 Road Lights Relay

79 Road Lights Switch

80 Head Light Dip Switch

81 LH Main Beam Light

82 RH Main Beam Light

83 LH Dip Beam Light

84 RH Dip Beam Light

85 LH Tail Light

86 LH Side Light

87 Socket (Dipper Light)

88 Number Plate Light

89 RH Tail Light

90 RH Side Light

91 Engine Running Relay

92 Front Working Lights Relay

93 Rear Working Lights Relay

94 Front Working Lights Switch

95 Rear Working Lights Switch

96 Front Working Lights

97 Rear Working Lights

98 Cab Interior Light/Switch

99 Beacon Switch

100 Beacon

101 Heater Switch

102 Heater Motor

103 Heater Resistor

104 Air Conditioning Pressure Switches

105 Air Conditioning Compressor Solenoid

*

Connections:

C From

C

on page C/4-1

E To

E

on page C/4-1

F To

F

on page C/4-1

G To

G

on page C/4-1

H To

H

on page C/4-1

J To

J

on page C/4-1 and C/4-9

K From

K

on page C/4-1

L From

L

on page C/4-1

N From

N

on page C/4-1

P From

P

on page C/4-1

Q From

Q

on page C/4-1

R To

R

on page C/4-9

Fuses:

A1 — A10

B1 — B10

C1 — C10

Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

9803/3280 Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 4

Circuit Schematic — Basic Machine (cont’d)

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 4

E

F

G

H

R

J

835

855

861

837

829

830

K

L

200

007

N

P

Q

133

001

C

407

59 60

66

M

62

M

65

68

M

M

70

69

INTEGRAL

INTERMITTENT

ECU

73

8

7

74

3

2

75

81

82

83

84

85

86

88

90

87

89

61 63

5 2

64

7

6 1 3 8

67

110

72

77

80

4

6

5 2

3 7

828

ROAD

LIGHTS

SWITCH

79

71

76

78

10 7

8 6

PRIMARY

FUSE 2

91

5 2

3

1

1853

96

94

6 3 7

5 2

4 6 1 3 7

5 2

95

8

92

4

2

6 8

6

4 2

8

93

97

98

7 3

8 2

99

M

100

M

102

103

101

A409181

852/30241sht2 Iss1

105

104

9803/3280

Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 5

Circuit Schematic — Synchro Shuttle

MANUAL

TRANSMISSION

Synchro Shuttle Transmission

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Circuit Schematic — Powershift

Note:

For further details on Powershift gearbox electrical circuits and connections, refer to

Section F — Electrical Connections

.

POWERSHIFT

Section C

4 — 5

D

3

2

10 7

8 6

5 6

7 10

12

D

7 8

3

2

10 7

5

6

4 2 5

1 3

9

1 5

4 2 3

8 6

883

12

15 17

18

20

16

9 7 10

6 8

19

9 7 10

6 8

10

2

5

1

3

10 7

13

8 6

2

5

8

1

3

10

8

7

6

11

9803/3280

1

10

8 6

9

4

5 4

852

3 1

A

TO NEUTRAL

START RELAY

9

B

TO FUSE

A5 852/30241sht3 Iss1

A409182

1

4

5 4

852

3 1

A

TO NEUTRAL

START RELAY

810

11

B

TO FUSE

A5

MISSION & STEER MODE OPTIONS

Purchased from www.WorkshopManuals.co.uk

14

852/30241sht3 Iss1

A409182

Issue 3*

Section C

4 — 6

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 6

Circuit Schematic — Synchro Shuttle and

Powershift

*

Synchro Shuttle Transmission

1 Parking Brake Warning Light Relay

2 Parking Brake Relay

3 Parking Brake Switch

4 Transmission Dump Relay

5 Transmission Dump Switch on Loader Lever

6 Transmission Dump Switch on Gear Lever

7 Forward Solenoid

8 Forward Relay

9 Forward/Reverse Selector Lever

10 Reverse Solenoid

11 Reverse Relay

12 Reverse Alarm

Connections:

A To

A

on page C/4-1

B From

B

on page C/4-1

D To

D

on page C/4-1

*

4 Speed Powershift Transmission

1 Parking Brake Warning Light Relay

2 Parking Brake Relay

3 Parking Brake Switch

4 Transmission Dump Relay

5 Transmission Dump Switch on Loader Lever

6 Drive Relay

7 Mainshaft Solenoid

8 Layshaft Solenoid

9 Interlock Relay

10 Forward Relay

11 Forward/Reverse Selector Lever

12 Reverse Alarm

13 Reverse Relay

14 Gear Selector Switch

15 Reverse Low Solenoid

16 Reverse High/Low Relay

17 Reverse High Solenoid

18 Forward Low Solenoid

19 Forward High/Low Relay

20 Forward High Solenoid

Connections:

A To

A

on page C/4-1

B From

B

on page C/4-1

D To

D

on page C/4-1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

4 — 7

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 7

Circuit Schematics — Options

Steer Mode — 4CX and 3CX Super (4x4x4)

1 Front Axle Proximity Switch

2 Rear Axle Proximity Switch

3 Steer Mode Selector Switch

4 Steer Mode Printed Circuit Board

5 Crab Relay

6 Crab/4 Wheel Steer Relay

7 2 Wheel Steer Relay

8 4 Wheel Steer Relay

9 4 Wheel Steer/Crab Mode Selector (part of 4)

10 2 Wheel Steer/4 Wheel Steer Mode Selector (part of 4)

11 Crab/4 Wheel Steer Solenoid

12 4 Wheel Steer Solenoid

13 4 Wheel Steer Indicator Light

14 Crab Solenoid

15 Crab Indicator Light

16 2 Wheel Steer Solenoid

17 2 Wheel Steer Indicator Light (Side Console)

18 2 Wheel Steer Indicator Light (Front Console)

*

Connections:

L From

L

on page C/4-1

M From

M

on page C/4-1

*

2 Wheel Steer/Brake Mode

1 LH Brake Light

2 RH Brake Light

3 Brake Light Switch

4 4 Wheel Braking Relay

5 Brake Mode Selector Switch

6 4 Wheel Drive/4 Wheel Braking Solenoid

7 Auto 2 Wheel Drive Relay

Connections:

S From

14

on page C/4-5 and

9

on C/4-13 as applicable

*

2 Wheel Steer/Brake Mode (Germany)

1 LH Brake Light

2 RH Brake Light

3 Brake Light Switch

4 4 Wheel Braking Relay

5 2 Wheel Drive Solenoid

6 Brake Mode Selector Switch

7 Auto 2 Wheel Drive Relay

Connections:

S From

14

on page C/4-5 and

9

on C/4-13 as applicable

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

4 — 8

3CX SUPER (4X4X4)

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

S

MODE

2 Wheel Steer/Brake Mode

2 Wheel Steer/Brake Mode (Germany)

Section C

4 — 8

5 7

4

STEER MODE

P.C.B.

6 8

9

10

3

11

12 14

13 15

16

17

18

1 2

1 2

5

6

9 7

10

6

8

7

3

4

5

2 4

3 1

S

1 2

5

7

10

6

8

7

3

6

4

5

2 4

3

1

S

9803/3280

M

IGNITION RELAY 1

L

IGNITION RELAY 2

852/30241sht3 Iss1

A409182

852/30241sht4 Iss1

A409183

Purchased from www.WorkshopManuals.co.uk

852/30241sht6 Iss1

A409185

Issue 2*

Section C

4 — 9

Circuit Schematics — Options

All Wheel Steer/Brake Mode

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Auxiliary and Hydraclamp Hydraulics Speedometer

9803/3280

1 2

5

3

9 7

10

6

6

8

1

5

1

3

2 4

5 9 10

6

7 10

6

8

3

4

5

2 4

3 1

4

6

1 3

S

7

5 2 8

7

2

8 1 3 6

7 2 5

4

7

8

3

4

7 2 5

8

101

1830

R

J

11

1

2

3

A409183

852/30241sht4 Iss1

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 9

Issue 2*

Section C

4 — 10

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 10

Circuit Schematics — Options

*

All Wheel Steer/Brake Mode

1 LH Brake Light

2 RH Brake Light

3 Brake Light Switch

4 4 Wheel Braking Relay

5 4 Wheel Drive Solenoid

6 Auto 2 Wheel Drive Relay

7 4 Wheel Drive Selector Switch

Connections:

J From

J

on page C/4-4

S From

14

on page C/4-5 and

9

on C/4-13 as applicable

Auxiliary and Hydraclamp Hydraulics

1 Jaw Relay

2 Push-Button Switch on Excavator Lever

3 Jaw Solenoid

4 Auxiliary Hydraulics Selector Switch

5 Hammer Solenoid

6 Hammer Relay

7 Footpedal Switch

8 Hydra-clamp Selector Switch

9 Hydra-clamp Solenoid

10 Power Sideshift Solenoid (if fitted)

11 Warning Buzzer

Connections:

R From

R

on page C/4-4

Speedometer Option

1 Speed Sensor

2 Speedometer

3 Illumination

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

4 — 11

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 11

Circuit Schematics — Options

*

Hand Held Tools

1 Selector Switch

2 Indicator Lamp

3 Roadbreaker Solenoid

*

Dedicated Quickhitch

1 Hitch Enable Switch

2 Quick-Hitch Relay

3 Warning Buzzer

4 Lever ‘hold-in’ Button

5 Lever ‘hold-in’ Button

6 Quick-Hitch Solenoid

*

Pole Planter

1 Selector Switch

2 Grab Solenoid

3 Rotation Solenoid

*

Smooth Ride System (SRS)

1 Accumulator Solenoids

2 Hose Burst Control Valve Relay (if fitted)

3 Selector Switch

4 Hose Burst Control Valve Solenoids (if fitted)

*

Return to Dig (Shovel Reset)

5 Lever ‘hold-in’ Solenoid

6 Ram Proximity Switch

7 Selector Switch

*

Hydraulic Speed Control (HSC)

1 Selector Switch

2 HSC Solenoid

3 HSC Relay

4 Control Lever Push-Button

Connections:

S From

14

on page C/4-5 and

9

on C/4-13 as applicable

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

4 — 12

Circuit Schematics — Options

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 12

2

3

1

Hand Held Tools

9803/3280

6

5

3

4

2

2

3

1

1

Dedicated Quick-Hitch

A409185

852/30241sht6 Iss1

Pole Planter

2

5

1 4

2

7 3 1 6

8 2 5

3

6

7 3

8 2

7

6

10

9

7

8

3

1

7 3 1

6

4

8 2 5

4

Smooth Ride System

(SRS)

Return To Dig

(Shovel Reset)

S

101

A409185

852/30241sht6 Iss1

Hydraulic Speed Control

(HSC)

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 13

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Circuit Schematics — 6 Speed Powershift (Shiftmaster)

Note:

For further details on Powershift gearbox electrical circuits and connections, refer to

Section F — Electrical Connections

.

AUTOSHIFT TRANSMISSION

Section C

4 — 13

9803/3280

3

10 11 12 13 14 15 16 17

6

974

7

AUTOSHIFT ECU

2

10 7

8 6

4

A

TO NEUTRAL

START RELAY

810

D

FROM PARKBRAKE

WARNING LIGHT

401

M

FROM IGNITION

RELAY 1

002

L

FROM IGNITION

RELAY 2

007

1

10

9

8

6

7 10

5

6 8

810

107

8

135

9

18

19

5

20

2 4

3 1

21

22

AWS ONLY 2WS ONLY

120 Ohm

RESISTOR

120 Ohm

RESISTOR

23

909

24

10

9

8

6

4 2 5

1

3

25

26

27

FUSE B1

A409184

852/30241sht5 Iss1

600

500

501

303

28

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

4 — 14

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 14

*

Circuit Schematic

— 6 Speed Powershift (Shiftmaster)

6 Speed Powershift Transmission

1 Parking Brake Warning Light Relay

2 Parking Brake Relay

3 Parking Brake Switch

4 Reverse Alarm

5 Reverse Alarm Relay

6 Speed Sensor

7 Electronic Control Unit

8 Forward/Reverse Selector Lever

9 Gear Selector Switch

10 Solenoid ‘T’

11 Solenoid ‘U’

12 Solenoid ‘V’

13 Solenoid ‘W’

14 Solenoid ‘X’

15 Solenoid ‘Y’

16 Solenoid ‘Z’

17 4 Wheel Drive Solenoid

18 Transmission Dump Switch

19 Transmission Dump Relay

20 Kick-down Switch

21 Throttle Switch

22 4 Wheel Drive Switch

23 Brake Mode Selector Switch

24 2 Wheel Braking Relay

25 Brake Lights Relay

26 Footbrake Switch

27 Warning Buzzer

28 Diagnostics Connector

Connections:

A To

A

on page C/4-1

D To

D

on page C/4-1

M From

M

on page C/4-1

L From

L

on page C/4-1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section C

4 — 15

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 15

Circuit Schematic — 214e Machines

Refer to pages C/4-16 and C/4-17.

Main Components:

1 Thermostart

2 Battery

3 Starter Switch

4 Neutral Start Relay

5 Starter Solenoid

6 Starter Motor

7 Ignition Relay ‘1’

8 Transmission Dump Relay

9 Forward/Reverse Selector Lever

10 Forward Relay

11 Reverse Relay

12 Forward Solenoid

13 Reverse Solenoid

14 Reverse Alarm

15 Transmission Dump Switch on Gear Lever

16 Transmission Dump Switch on Loader Lever

17 Parking Brake Relay

18 Parking Brake Switch

19 4 Wheel Drive Selector Switch

20 4 Wheel Drive Solenoid

21 Brake Light Switch

22 4 Wheel Braking Relay

23 LH Brake Light

24 RH Brake Light

25 Engine Shut-Off Solenoid (ESOS)

26 Heater Switch

27 Heater Resistor

28 Heater Fan Motor

29 Rear Washer/Wiper Switch

30 Rear Washer Motor

31 Rear Wiper Motor

32 Cab Interior Light/Switch

33 Face Level Fan/Switch

34 Rear Proximity Switch

35 Wheel Align Switch

36 Hammer Isolaton Switch

37 Hammer Foot Switch

38 Hammer Solenoid

39 Front Washer/Wiper Switch

40 Front Washer Motor

41 Front Wiper Motor

42 Front Horn Switch

43 Front Horn

44 Hazard Warning Switch

45 Indicator Flasher Unit

46 Direction Indicator Switch

47 LH Front Indicator

48 LH Rear Indicator

49 RH Front Indicator

50 RH Rear Indicator

9803/3280

51 Engine Coolant Temperature Gauge

52 Engine Coolant Temperature Sender

53 Fuel Gauge

54 Fuel Gauge Sender

55 Tachometer

56 Hourmeter

Connections:

A To

A

on page C/4-17

B From

B

on page C/4-17

C From

C

on page C/4-17

D From

D

on page C/4-17

E From

E

on page C/4-17

F From

F

on page C/4-17

G From

G

on page C/4-17

H From

H

on page C/4-17

J From

J

on page C/4-17

K To

K

on page C/4-17

L From

L

on page C/4-17

M To

M

on page C/4-17

N To

N

on page C/4-17

P To

P

on page C/4-17

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

4 — 16

Circuit Schematic — 214e Machines

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 16

9803/3280

A

1

23

5

6

4

5 2 4

8 6

15

13

12

14

16

10

5 2 4

11

10 7 9

18

20

24

3 1 8 6

9

9

17

7 10

2

3

19

7

9 7 10

22

6

8

8

6 8

5 2 4

25

27

26

28

1

3 4 6 7

2 5

8

30

M

31

M

5 2

29

7

6 1 3 8

32

8

3 1

21

33

2

3

34

35

7

8

38

37

36

3

2 8

7

40

M

41

M

5 2

39

7

6 1 3 8

43

42

47

48

49

50

1 3 7

46

2

2

45

6

4

8

828

5 17 2

10

44

18 1 3

52

54

51 53

55

56

412

407

B

C

401

D

106

E

3

9 8 7 3 4 5 6

1 2

FUSE P3

FUSE P2

FUSE P1

FUSE P4

FUSE P1 40A

FUSE P2 50A

FUSE P3 50A

FUSE P4 60A

4 2 5

6

8

7

001

200D/200M

200G

200E/200R

BATTERY FEED

830

828

F

G

829

007

011

H

J

K

L

M

N

P

331/17034sht 1

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 17

Circuit Schematic — 214e Machines (cont’d)

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

OPTIONS

E

106

F

G

830

828

H

J

K

L

M

N

P

829

007

011

200D/200M

200G

200E/200R

A

B

C

D

412

407

401

6062646668

16 3 18 12 9 11 10

17

407

411

70

W

71

72

69

57 585961636567

7 SIDE CONSOLE

INSTRUMENTS

BATTERY FEED

5 2 4

73

8 6

76

79

6 3 7

5 2

75

4 6 1 3 7

5 2

78

8

74

4

2

5

6 8

4 2

5

77

6 8

80

84

85

86

87

89

88

90 91

92

1 3

6 3 7

5 2

82

6

81

8

2

4

2

5

83

7

8

102

3 7

2

101

8

H

‘SRS’

SMOOTH RIDE

SYSTEM

100

Section C

4 — 17

331/17034sht 2

Issue 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section C

4 — 18

www.WorkshopManuals.co.uk

Electrics

Basic System Operation

Section C

4 — 18

Circuit Schematic — 214e Machines (cont’d)

Main Components:

57 Alternator Warning Indicator Light

58 Parking Brake Indicator Light

59 Engine Coolant Temperature Indicator Light

60 Engine Coolant Temperature Switch

61 Transmission Oil Temperature Indicator Light

62 Transmission Oil Temperature Switch

63 Engine Oil Pressure Indicator Light

64 Engine Oil Pressure Switch

65 Transmission Oil Pressure Indicator Light

66 Transmission Oil Pressure Switch

67 Air Filter Blocked Indicator Light

68 Air Filter Restriction Switch

69 Warning Buzzer

70 Alternator

71 Radio Socket

72 Cab Auxiliary Power Socket

73 Ignition Relay ‘2’

74 Front Working Lights Relay

75 Front Working Lights Switch

76 Front Working Lights

77 Rear Working Lights Relay

78 Rear Working Lights Switch

79 Rear Working Lights

80 Beacon/Strobe Light Socket

81 Road Lights Relay

82 Road Lights Switch

83 Head Light Dip Switch

84 RH Dip Beam Light

85 LH Dip Beam Light

86 LH Main Beam Light

87 RH Main Beam Light

88 LH Tail Light

89 LH Side Light

90 Socket (Dipper Light)

91 RH Tail Light

92 RH Side Light

Options:

100 SRS Smooth Ride System

101 Selector Switch

102 Accumulator Solenoids

Connections:

A From

A

on page C/4-16

B To

B

on page C/4-16

C To

C

on page C/4-16

D To

D

on page C/4-16

E To

E

on page C/4-16

F To

F

on page C/4-16

G To

G

on page C/4-16

H To

H

on page C/4-16

J To

J

on page C/4-16

K From

K

on page C/4-16

L To

L

on page C/4-16

M From

M

on page C/4-16

N From

N

on page C/4-16

P From

P

on page C/4-16

Fuses:

A1 — A10

B1 — B10

C1 — C10

Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

19 — 1

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

19 — 1

Electrical Testing Methods

— Using a Multimeter

These instructions are intended to cover the use of the recommended multimeters.

OFF

V/A

V/A

A

A

B

A171900

S153070

1

Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a » – «, or «E» or marked as «COMMON» or «COM»). The red test lead should be plugged into the red socket marked with «+», «V» or «

Ω

«.

2

When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease, dirt, and corrosion as these can cause a false reading.

3

When measuring voltage:

Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about to measure.

e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the next range higher, 20V for instance.

If the meter is set to a range that is too low, it may be damaged.

e.g. setting to the 2V range to measure 12V.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

19 — 2

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

19 — 2

9803/3280

Purchased from www.WorkshopManuals.co.uk

S153070

Issue 1

Section C

19 — 3

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

19 — 3

Electrical Testing Methods

— Using a Multimeter

1 Measuring DC Voltage

a

On the FLUKE 85

Turn the switch to position

B

.

b

On the AV0 2003

Move the right slider switch to position

A

, and the left hand slider switch to the appropriate range.

c

On an analogue meter

Turn the dial to the appropriate DC Volts range.

Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.

2 Measuring Resistance

Make sure there is no power to the part of the circuit you are about to measure.

Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not matter which way round the two probes are placed.

a

On the FLUKE 85

Turn the switch to position

C

and check that the

Ω sign at the right hand side of the display window is on. If the

F

sign is on instead, press the blue button

G

to change the reading to

Ω

.

Touch the meter lead probes together and press the

REL

³ key on the meter to eliminate the lead resistance from the meter reading.

b

On the AV0 2003

Move the right hand slider switch to position

B

, and the left hand slider switch to the appropriate Ohms (

Ω

) range.

c

On an analogue meter

Move the dial to the appropriate Ohms ( Ω ) range.

3 Measuring Continuity

Make sure there is no power to the part of the circuit you are checking for continuity.

Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed.

a

On the FLUKE 85

Turn the switch to position

C

and check that the beeper symbol appears at the left hand side of the display window.

If the

F

sign is on instead, press the button labelled

F

in the meter drawing.

If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.

b

On the AV0 2003

Move the right hand slider switch to position

B

, and the left hand slider switch to position

C

.

If there is continuity (i.e. very low resistance) between two points the buzzer will sound.

c

On an analogue meter

Turn the dial to the lowest Ohms (

Ω

) range.

If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section C

19 — 4

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

19 — 4

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

19 — 5

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

19 — 5

Electrical Testing Methods

— Using a Multimeter

4 Testing a Diode or a Diode Wire

A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving.

a

On the FLUKE 85

Turn the switch to position

D

.

Press the

HOLD

button and check that the

H

sign appears at the top right hand side of the display window.

Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty.

Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read

O.L

., the diode or diode wire is faulty.

Press the

HOLD

button and check that the

H

sign disappears from the right hand side of the display window.

b

On the AV0 2003

Move the right hand slider to position

A,

and the left hand slider switch to position

C

.

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty.

Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the Avometer does not read «1» the diode is faulty.

c

On an analogue meter

Select the Ohms 1000s (1k) range.

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. The meter should read 20-400 K

Ω

, if it reads more than this the diode is faulty.

Select the Ohms 100s range.

Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. The meter should read 300-400

Ω

, if it reads less than this the diode is faulty.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

20 — 1

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

20 — 1

Battery

Maintenance

To ensure that the battery provides optimum performance the following steps should be observed:

1

Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.

2

When applicable — never allow the electrolyte level to fall below the recommended level — 6 mm (1/4 in) above the plates. Use only distilled water for topping up.

3

Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened)

— this condition makes recharging the battery very difficult.

Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery:

NEVER boost-charge a maintenance free battery.

NEVER charge a maintenance free battery at a voltage in excess of 15.8 Volts.

NEVER continue to charge a maintenance free battery after it begins to gas.

Safety

!

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

Do the following if electrolyte:

GETS INTO YOUR EYES

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

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

5-3-4-3/1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

20 — 2

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

20 — 2

Battery (cont’d)

Testing

This test is to determine the electrical condition of the battery and to give an indication of the remaining useful

‘life’.

Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to

27°C).

Ensure that the battery is completely disconnected from the vehicle.

Connect up the battery tester (part no. 993/85700) as follows:

1

Set the CHECK/LOAD switch

A

to OFF.

2

Set rocker switch

B

to the battery voltage (12V).

3

Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative

(-) terminal.

4

Set the CHECK/LOAD switch

A

to CHECK to read the battery no-load voltage which should be at least 12.4

volts.

Fault Diagnosis

Battery Tester Readings

1

CHECK: 0 — 12.6 Volts

LOAD: less than 6 Volts

2

CHECK: 6 — 12.4 Volts

LOAD: less than 9 Volts and falls steadily but remains in yellow zone.

3

CHECK: less than 10 Volts

LOAD: less than 3 Volts

4

CHECK: more than 11 Volts

LOAD: 6 — 10 Volts steady

5

Set the CHECK/LOAD switch

A

to LOAD and hold down for 5 — 10 seconds until the meter reading stabilises. The reading should be at least 9 volts.

Note:

Do not hold the switch in the LOAD position for more than 10 seconds.

6

If the foregoing tests are unsatisfactory, consult Fault

Diagnosis below.

Remedy

Renew battery

A

B

239510

Recharge and re-test. If tests still unsatisfactory renew battery.

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

Charge battery which will probably recover.

Specific Gravity Testing

The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hydrometer, when the electrolyte temperature is 15

°C (60 °F). If the battery has recently been on charge, wait approximately one hour (or slightly discharge the battery) to dissipate the surface charge before testing.

Specific Gravity at 15 °C (60 °F)

Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell.

If the electrolyte temperature is other than 15 °C (60 °F) a

‘correction factor’ must be applied to the reading obtained.

Add 0.07 per 10 °C (18 °F) if the temperature is higher than

15 °C (60 °F) and subtract the same if the temperature is lower.

Fully Charged Half Discharged Fully Discharged

Ambient temperature up to 27 °C (80 °F)

Ambient temperature above 27 °C (80 °F)

1.270 — 1.290

1.240 — 1.260

1.190 — 1.210

1.170 — 1.190

1.110 — 1.130

1.090 — 1.110

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section C

21 — 1

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

21 — 1

Alternator

General Description

The alternator is a three phase generator having a rotating field winding and static power windings.

When the start switch is turned on, current from the battery flows by way of the ‘No Charge’ warning light to the field winding. This creates a magnetic field which supplements the residual magnetism in the rotor poles. As the engine is started, the fan belt drives the rotor and alternating current is generated in the power windings as they are cut by the rotating magnetic field. Output is controlled by a solid state regulator which varies the field current in accordance with electrical demand.

Servicing is restricted to periodic inspection of slip ring brushes. Bearings are ‘sealed for life’.

Service Precautions a

Ensure that the battery negative terminal is connected to the earthing cable.

b

Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes.

c

Main output cables are ‘live’ even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator.

d

During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables).

e

If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained.

Take care to connect batteries positive to positive, negative to negative.

Connect the leads to the meter and set the meter to the relevant range as follows.

AVO 2002 Red lead to volts (middle) socket on meter.

Black lead to negative on meter.

RH slider to DC voltage.

LH slider as shown in the illustration.

AVO 2003 Red lead to amps socket (marked

A

) on the meter.

Black lead to negative on meter.

RH slider to DC voltage

LH slider to 200 Shunt

FLUKE 85 Red lead to volts socket (marked V )on meter.

Black lead to COM socket on meter.

Set dial to mV.

Start the engine and run at maximum speed (see

Technical

Data

). Meter should show maximum alternator output in

Amps (see

Technical Data

).

Note:

The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly.

A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability.

a

Defective suppression capacitor.

b

Dirty slip rings or worn brushes.

c

Defective regulator.

f d

Defective rectifier.

e

Open or short — circuited field (rotor) windings.

Open or short — circuited power (stator) windings.

To check for fault

a

, disconnect the capacitor and repeat the charging test. Renew the capacitor if necessary.

To check for faults

b

and

c

, remove the regulator and brush box assembly. Check the condition of the brushes and, if necessary, clean the slip rings using extra-fine glasspaper.

The regulator may only be checked by substitution.

Faults

d

,

e

, and

f

may be checked only by removing and dismantling the alternator for further testing.

Charging Test

Ensure that all battery and alternator connections are in place, secure and making good metal — to — metal contact, especially the ‘earth’ connections to chassis and engine.

Make sure that the alternator drive belt tension is correctly adjusted.

If the battery is in a fully charged condition, switch on the working lights for 3 minutes before commencing the test.

Alternatively, operate the starter for a few moments with the engine shut off solenoid (ESOS) fuse removed (refer to fuse identification pages).

Install a 100 amp open — type shunt between the battery positive lead and the battery positive terminal.

Connect a multimeter positive lead to machine side of the shunt and negative lead to battery side of the shunt.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S08346

Issue 1

Section C

22 — 1

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

22 — 1

Starter Motor

Starting Circuit Test

Before carrying out the voltmeter tests, check the battery condition (see Battery Testing) and ensure that all connections are clean and tight.

To prevent the engine starting during the tests ensure that the engine stop fuse is removed, (refer to fuse identification page).

Check the readings in the following sequence using a voltmeter. Unless otherwise stated, the readings must be taken with the starter switch held in the ‘start’ position (‘HS’) and the transmission forward/reverse selector in neutral.

Note:

Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least two minutes between starts.

Test 1

Connect the voltmeter across the battery terminals. Reading in ‘start’ position: 10.0V approximately. Minimum permissible reading in ‘start’ position 9.5V.

A low reading probably indicates a fault in the starter motor.

Test 3

Connect the voltmeter between the solenoid terminal

C

and a good earth. Minimum permissible reading in ‘ start’ position: 8.0V.

C

S151010

Test 3a

If the reading is less than specified, connect the voltmeter between the neutral start relay terminal

D

and earth. An increase in reading to 8.0V indicates a fault in the wiring from the start relay to the solenoid.

S151000

Test 2

Connect the voltmeter between the starter main terminal

A

and the commutator end bracket

B

. In the ‘start’ position, the reading should not be more than 0.5V below the reading obtained in Test 1. Minimum permissible reading in ‘ start’ position 9.0V.

If the reading is within this limit, continue to Test 3. If the reading is outside the limit, proceed to Tests 4 and 5.

F

N

R

A

C

B

H

810C

842

B

A

S151030

9803/3280

Purchased from www.WorkshopManuals.co.uk

600V

D

E

004

+

—

A215660

Issue 1

Section C

22 — 2

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

22 — 2

Starter Motor (cont’d)

Starting Circuit Test (cont’d)

Test 3b

If the reading between terminal

D

and earth is below 8.0V, connect the voltmeter between terminal

E

and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection.

If the reading between

E

and earth is less than 8.0V, the fault must be in either the starter switch or in the wiring between the solenoid, starter switch, and the start relay.

Test 4

Connect the voltmeter between battery negative and starter earth connection

B

. The reading in the ‘start’ position should be practically zero, maximum permissible reading 0.25V.

Test 5

Connect the voltmeter between battery positive and the starter main terminal

A

. With the starter switch ‘ off’ , the voltmeter should indicate battery voltage, but it should fall to practically zero when the switch is turned to the ‘ on’ position, maximum permissible reading 0.25V.

A

S151050

B

S151040

Test 5a

If the reading is above 0.25V, a high resistance is present in the insulated lead or in the solenoid. Connect the voltmeter between the battery positive and solenoid connection

H

. If the voltmeter now reads zero with the switch closed, the fault is in the solenoid.

If the reading is above 0.25V, a high resistance in the earth lead or connections is indicated.

H

Finally refit the engine stop fuse.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

23 — 1

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

23 — 1

Wiring Harness

Introduction

Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, although unlikely with present wiring harnesses, repair or replace specific individual wires within a harness.

This will also apply to other machines in addition to those of

JCB manufacture.

To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used.

Note that JCB harnesses have an International Protection rating of 67 (I.P.67).

The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.

!

CAUTION

When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular circuit. It is unacceptable to simply increase the fuse rating as this can cause overloading and consequential failure of wiring, along with failure of integral circuit components, which the fuse is protecting.

ELEC 2 — 1

!

WARNING

In addition to the warnings incorporated into the procedure, extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair, i.e. other wires, floor panels, floor mats, sound proofing, paintwork. etc. This tool should not be used in any restricted location prohibiting the use of «Naked

Flames’ or where risk of explosive gas or similar safety parameters apply. No other heat source should be used to attempt a sealed joint .

ELEC 2 — 2

!

CAUTION

When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not touch the reflector until it has had time to cool down after switching off. If flame reappears at the reflector when the heater is in use, the catalytic element is damaged or used up. Stop work immediately and replace the heater.

ELEC 2-3

Tools Required

892/00350 Butane Heater assembly

892/00349 Crimp tool

892/00351 Splice 0.5-1.5 mm (Red)

892/00352 Splice 1.5-2.5 mm (Blue)

892/00353 Splice 3.0-6.0 mm (Yellow)

1

1

50

50

50

Repair Procedure

1

Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed above, the dimension is 7mm.

2

Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool

X

, part number

892/00349.

Note that each of the splices detailed is colour-coded to make size and range readily visible. They are secured using the corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size.

3

With the Butane heater assembly, 892/00350, seal the connection using the procedure on the next page.

….continued

X

7

9803/3280

Purchased from www.WorkshopManuals.co.uk

S189530

Issue 1

Section C

23 — 2

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

23 — 2

Wiring Harness — Repair Procedure (cont’d)

With the Butane Heater assembly 892/00350, seal the connection using the following procedure.

a

Remove the cap

A

from the end of the disposable gas cartridge

B

.

A

B

S189490/1

b

Before assembling the gas cartridge to the reflector element

C

, turn the red ring

D

to the left, (in the direction of the minus sign marked on the ring).

C

D c

Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge.

Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together. A click will be heard.

S189490/2

d

Turn the small ring

E

so that the air holes at

F

are completely closed.

S189490/3

9803/3280

S189490/4

Purchased from www.WorkshopManuals.co.uk

F

E

Issue 1

Section C

23 — 3

www.WorkshopManuals.co.uk

Electrics

Service Procedures

Section C

23 — 3

Wiring Harness — Repair Procedure (cont’d) e

Turn the red ring

D

to the right (in the direction of the plus sign) in order to turn on the gas.

IMPORTANT:

Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartridge is held in the hand for a long time.

The temperature difference between the cartridge and the reflector element may cause long yellow flames to appear on ignition.

D

S189490/5

f

Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.

Note:

The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full.

Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red.

Then turn the small ring

E

until the air holes at

F

are completely open. The tool is ready for use.

The heater can be used in two modes:

g

Side wings

G

down, reflector head completely open. In this mode the infra-red heat waves are dominant

(recommended for the light coloured plastic splices).

Side wings

G

up (see fig at step

h

), reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).

S189490/6

F

E

G

S189490/7

h

To switch off the heater, turn the red ring

D

to the left (in the direction of the minus sign).

G

D

9803/3280

S189490/8

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

30 — 1

www.WorkshopManuals.co.uk

Electrics

Alternator

Section C

30 — 1

Removal and Replacement

Disconnect cables from rear of alternator, remove bolts

A

,

B

and

C

and withdraw unit from machine.

Replace by reversing the removal sequence. Position the alternator until belt deflection is approximately 10mm (3/8 in) before tightening bolts

B

and

C

. It may be necessary to slacken bolt

D

to allow full movement of alternator. Tighten bolt

A

last of all.

A

B

S099850A

9803/3280

Purchased from www.WorkshopManuals.co.uk

C

D

S099850B

Issue 1

Section C

40 — 1

www.WorkshopManuals.co.uk

Electrics

Starter Motor

Section C

40 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

S02043C

Issue 1

Section C

40 — 2

www.WorkshopManuals.co.uk

Electrics

Starter Motor

Section C

40 — 2

Removal and Replacement

Disconnect cables and remove battery. Remove cables from main starter terminal and solenoid terminal. Using special tool 825/00410 (and adapter 825/99833 if required) unscrew three securing nuts and remove starter motor.

Replace by reversing the removal sequence.

Dismantling

Note:

Dismantle only to item

34

unless the field windings are to be renewed. Test the windings electrically before removing them from the motor yoke

15

.

Using a slotted steel tube, displace ring

23

to permit withdrawal of ring

22

.

Allow brake shoes

28

to remain in the end plate

11

unless requiring renewal.

Inspection

Renew brushes

14

and

14A

if their length is less than 8mm

(0.3in.).

Clean the commutator

A

. If individual copper bars are burned or eroded the armature has broken windings and must be renewed. Otherwise polish with fine grade glass paper (not emery). Renew armature if commutator diameter is 38mm (1.5in.) or less.

Check the field windings for open circuits by connecting a multimeter set to measure resistance (see

Electrical Testing

Methods

) between the stud terminal

B

and each positive brush

14A

in turn. A high or infinity reading indicates an open circuit. Similarly, connect the meter between brushes

14A

and the motor yoke

15

. Any reading other than infinity indicates a short circuit between the coils and the yoke.

Renew the coils as necessary, removing screws

36

with a pole shoe screwdriver C50 (obtainable from Lucas dealers).

Check bronze bushes

32

and

34

for wear.

Assembly

Align crosspin

C

with the notches in the brake shoes

28

before assembling brush carrier and back plate to motor yoke. Ensure that brushes

14A

are correctly located in the insulated brush boxes.

Smear drive shaft splines and operating collar bearing surface with JCB MPL Grease before assembly. Assemble operating fork

19

with curved face toward the armature.

Set the movement of drive pinion

24

by connecting a 6v battery and switch as shown. Operate switch and check dimension

D

. Adjust to 0.13-1.14mm (0.005-0.045in.) by slackening locknut

17

and rotating eccentric pin

18

as necessary. Re-tighten locknut.

D

S02303A

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

145 — 1

www.WorkshopManuals.co.uk

Electrics

Harness Data

Section C

145 — 1

Earth Points

DR2

DR2

A

C47

FB1

H

9803/3280

A

E

E

E1

F

MB

G

F1

F2

F

F

NJ

E

E2

A405010

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

145 — 2

www.WorkshopManuals.co.uk

Electrics

Harness Data

Section C

145 — 2

Earth Points

Introduction

The illustartion opposite shows the machine electrical earth point locations. This can be useful when tracing electrical faults, typically when several electrical devices are malfunctioning.

Key

Decription

A

Earth strap, cab. From DR2 to cab frame.

C47

Earth, cab roof harness.

DR2

Earth, side console harness.

E

Earth cable E, cab to engine.

E1 Earth cable E, cab end.

E2 Earth cable E, engine end.

F

Earth cable F, engine to battery.

†

F1 Earth cable F, engine end.

F2 Earth cable F, battery end.

FB1

Earth, front console harness.

G

Earth strap, starter motor.

H

Earth, work lights harness.

MB

Earth at starter motor, engine/mainframe harness.

NJ

Earth at battery, engine/mainframe harness.

Access

Remove loader control console.

Remove — inside cab: ‘B’ post covers, roof lining.

Outside cab: lift moulded roof panel.

Remove side console.

Undo one side on the flexible grey moulding at the front on the cab (outside).

Remove engine side panel.

Remove engine side panel.

Remove front grille.

Remove front console, see

Section B, Body and Framework

.

Remove engine side panel.

Remove — inside cab: ‘B’ post covers, roof lining.

Outside cab: lift moulded roof panel.

Remove engine side panel.

Remove front grille.

†

The illustration opposite shows the battery earth cable connection for machines not fitted with a battery isolator switch. Machines fitted with a battery isolator

P

have earth cable connections as shown below.

F

P

A404120

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

150 — 1

www.WorkshopManuals.co.uk

Electrics

Harness Data

Section C

150 — 1

Drawings

Introduction

The following drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness.

*

Harness Interconnection

The harness number refers to and corresponds with the annotations in the schematic drawing on the adjacent page.

Harness No.

Issue Remarks Page

1 Front Console

721/10940

721/10937

2 Side Console

721/10936

721/10970

3 Cab Roof

721/10966

721/10965

1

2

1

3

4 speed Powershift / Synchro Shuttle

6 speed Powershift (ShiftMaster)

Machines up to S/No. 933756

Machines from S/No. 933757

1

1

USA only

Not USA

4 Interior Light, Radio Speakers

721/11050 1

5 Steer Controls

721/10968

721/10967

1

1

Not crab steer

6 Cab Link

721/10943

721/10942

7 Transmission

721/10941

721/10938

721/10939

8 Engine/Mainframe

721/10935

1

2

1

1

1

11 Auxiliary

721/10974

2

9 Rear Lights, Hydraclamp

721/10944 1

10 Rear Horn, Alarm

721/10946

721/10947

1

1

1

6 speed Powershift (ShiftMaster)

4 speed Powershift / Synchro Shuttle

6 speed Powershift

Synchro Shuttle

4 speed Powershift

Sideshift

Sideshift

Centre mount

Excavator

151 — 1

151 — 3

153 — 1

153 — 5

155 — 1

155 — 3

155 — 5

157 — 1

157 — 2

160 — 1

160 — 3

160 — 5

160 — 7

160 — 8

165 — 1

165 — 3

165 — 4

165 — 5

165 — 6

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section C

150 — 2

Harness Interconnection

(continued)

www.WorkshopManuals.co.uk

C1

NH LB

Electrics

Harness Data

CB

CA

C40

CR

3

ENGINE/MAINFRAME

HARNESS — Main components connected to this harness:

Alternator

Starter motor

Primary fuses

Front steer proximity switch

Shovel reset proximity switch

ESOS

Smooth ride solenoids

Air conditioning compressor

8

TRANSMISSION HARNESS —

†Connector C10 is labelled GA on Synchro Shuttle machines.

Main components connected to this harness:

Gearbox control solenoids

7

CA

NH

C10† LC

4

CP

CS

SIDE CONSOLE HARNESS —

Main components connected to this harness:

Side console instruments

Side console switches

Side console warning lamps

Starter switch

Heater controls

Fuses and Relays

Immobiliser (if fitted)

N

G

2

B

S

6

CB

LB

FRONT CONSOLE HARNESS —

Main components connected to this harness:

Left and right column switches

Gearbox control relays

ShiftMaster E.C.U. (if applicable)

Front wiper motor

Front console switches

Speedometer

Front console warning lamps

1

FA LA

LA

C10

C10

ME

9

11

10

5

Access Details

C1

C2

C3

C4

C5

C6

C7

Inside cab — remove loader control console.

Inside cab — remove side console.

Inside cab, rear of heater unit

Remove side console.

Inside cab — remove front/steer console.

Outside cab — lift bonnet

Under machine above gearbox. (Powershift shown).

Under machine, located in cab floor above rear wheel remove protective cover.

A408780

C4

FA

1

C5

A408820

6

LA

8

6

6

1

6

LC

C10

4

C2

3

CP

CS

2

8

C40

CR

7

2

2

9

11

10

5

7

C6 C7

Section C

150 — 2

2

S

B

G

N

C3

LA C10 C10 ME

9

11

10

5

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section C

Electrics

151 — 1 Harness Data

Harness Drawing — Front Console, 4 speed Powershift, Synchro Shuttle, page 1 of 2 — CAD 721/10940 Issue 1

FH

FJ

FK

FE

FF

FG

Key to Connectors:

FA

FB

FC

FD

Bulkhead Plug

Front Cab Earth

Steer Mode Unit

Forward Relay

Forward H.L

Reverse Relay

Reverse H/L

Drive Relay

Interlock Relay

Transmission Dump

Blank

4WS

Auto 2WD

Link

Diodes

FT

FU

FV

FW

FX

FY

FZ

GA

FL

FM

FN

FP

FR

FS

FSA

FSB

Column Switch — Powershift

Footbrake Switch

Wiper Motor

Column Switch — RH

Front Warning Lights

Speedometer

Speedometer Illumination

Speedometer Illumination

Steer Mode Switch

Brake Mode Switch

Hazard switch

Main Lights

2/4WD Select

Fog Light Switch

Brake Link Socket

Brake Link Pin

Section C

151 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

721/10940_1

Issue 2*

www.WorkshopManuals.co.uk

Section C

Electrics

151 — 2 Harness Data

Harness Drawing — Front Console, 4 speed Powershift, Synchro Shuttle, page 2 of 2 — CAD 721/10940 Issue 1

Section C

151 — 2

FW4

FF4

SR

SW

SF

SE

SN

FV2

FV18

FW3

SP

FV1

FW2

FV3

FL 8

FW5

SS

FP 9

FP 13

—

FA 41

—

—

—

FR2

FR7

FR8

FR1 1

FA 59

FS2

FY 2

FY 3

FS1

—

FN8

SM

SA

SA

SK

—

—

—

—

DEST

FC3

FL 6

FC4

FC6

SB

FD7

SK

SD

FT 1

FK1 1

FD9

ST

FE7

SG

FE9

FF2

FH1

803

828

110

104

311

300

814

127A

839

818G

933

805D

802

811

853

811/849

850

126A

1133A

851

830C

845

825D

812

934

819

820

BULKHEADPLUG

WIRE

824B

SIZE

1.0

810E

826B

1.0

1.0

815

812/848

1858

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

0.6

0.6

1.0

1.0

1.0

1.0

2.0

107

833

836

837D

855D

861D

411A

405

974

868

835

—

106N

303C

—

—

—

—

—

806D

600DP

600DN

934B

—

—

405

—

1.0

1.0

—

—

—

—

—

0.6

—

—

—

0.6

0.6

0.6

0.6

1.0

1.0

—

1.0

1.0

1.0

1.0

FRONT CABEARTH

WIRE SIZE

621 6.0

DEST

SA

23

24

25

26

27

28

29

30

31

32

33

18

19

20

21

22

13

14

15

16

17

FA

TERM

1

2

3

4

5

6

7

8

9

10

11

12

34

35

36

37

38

39

40

41

45

46

47

42

43

44

48

49

53

54

55

56

57

58

59

60

50

51

52

FB

TERM

1

AA

AA

AA

AA

AB

AA

AA

AA

AA

AA

AA

AA

AA

AA

AB

AB

AB

AB

AB

AB

AA

AA

AA

AA

AA

AB

AB

AB

AB

AB

AA

AA

AA

AA

AA

AA

AA

AA

A,B

TYPE

AA

AA

AA

AC

AA

AA

AA

AA

AA

AA

AA

AC

AC

AC

AC

AC

AC

AA

AC

AA

AA

AC

—

TYPE

C,X

6

7

8

9

10

2

3

4

5

FG

TERM

1

2

3

4

5

6

7

8

9

10

FE

TERM

1

2

3

4

5

6

7

8

9

10

FF

TERM

1

2

3

4

5

6

7

8

9

10

4

5

6

7

8

FC

TERM

1

2

3

FD

TERM

1

STEERMODEUNIT

WIRE

822

SIZE

0.6

821

824B

826B

823

845

825B

600L

0.6

1.0

1.0

0.6

1.0

1.0

1.0

WIRE

999

850

DRIVERELA Y

SIZE

1.0

1.0

883B

851

0.6

1.0

600AG

999

0.6

INTERLOCKRELA Y

1.0

1858B

1858C

846B

600LF

1.0

0.6

1.0

0.6

DEST

FF6

FA 16

SU

FA 19

SA

FF1

ST

ST

FD2

SA

—

—

—

—

—

WIRE

107AD

—

TRANSDUMP

SIZE

1.0

—

107AL

852N

934D

0.6

1.0

0.6

BLANK

—

—

—

—

—

—

—

—

—

—

DEST

SS

—

SS

FD1

SK

FORWARDRELA Y

WIRE

852N

SIZE

1.0

DEST

FG4

852P

846

846B

1.0

1.0

1.0

809

—

0.6

—

600AC 0.6

846

FORWARDH/L

1.0

FE1

FD6

FF9

FL 4

—

SA

812

884D

812/848

600AE

1.0

0.6

1.0

0.6

FD2

FA 6

SH

FA 11

SA

REVERSERELA Y

WIRE

852P

1858A

SIZE

1.0

1.0

808

—

600AD

0.6

—

0.6

REVH/L

1.0

1858D

811

884C

811/849

600AF

1.0

0.6

1.0

0.6

DEST

FD1

ST

FL 10

—

SA

ST

FA 13

SH

FA 15

SA

DEST

FT 5

FT 6

FA 1

FA 3

FT 3

FA 4

SB

SA

F

TYPE

AT

AT

AV

—

AV

AT

AT

AV

AV

AV

F

TYPE

AT

—

AV

AV

AV

AT

AT

AV

AV

AV

F

TYPE

AT

AT

AV

AV

AV

AT

AT

AV

AV

AV

D,E

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

F

TYPE

AU

—

—

—

—

—

AU

AV

—

AV

G,H

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AT

AT

AV

AV

AV

AF,AG

AF,AG

AK

AK

AF,AG

AF,AG

AK

AK

J,K

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AH,AJ

J,K

TYPE

AK

AK

AK

AF,AG

AF,AG

AH,AJ

AF,AG

AF,AG

AF,AG

L,M

TYPE

AD

AD

AD

1

2

3

4

5

9

10

11

7

8

12

13

14

FL

TERM

1

2

3

4

5

6

FM

TERM

1

2

3

FH

TERM

FK

TERM

1

4

5

6

2

3

7

8

9

10

11

12

13

14

WIRE

126A

126

933B

107P

922E

877

8

9

10

7

6 107/922

1855

818H

854E

600AB

9

10

6

7

8

FJ

TERM

1

2

3

4

5

WIRE

857B

107AE

922C

922A

107/922

818E

933C

858K

818F

854H

4WB

SIZE

1.0

1.0

1.0

0.6

1.0

0.6

AUTO2WD

1.0

1.0

0.6

1.0

0.6

FJ5

GA 10

SF

SJ

SA

WIRE

856A

856B

858A

883E

884

884A

934C

804A

—

—

815

806

—

—

COLUMNSWITCH-P/SHIFT

WIRE SIZE

—

—

—

—

—

—

809

857B

810E

107R

814

856

808

110H

883

858

107A

0.6

0.6

1.0

0.6

2.0

0.6

0.6

2.0

0.6

0.6

0.6

DEST

—

—

—

FD3

FJ1

FA 2

SS

FA 32

SC

FE3

SP

SU

SL

SS

SK

FV17

—

—

FA 10

SM

—

—

DEST

SC

SC

SL

SU

SH

SH

FOOTBRAKESW

WIRE SIZE

126

628

877

0.6

0.6

0.6

DEST

FH1

SA

FH5

LINK

SIZE

0.6

1.0

1.0

1.0

1.0

0.6

1.0

1.0

0.6

1.0

DIODES

SIZE

0.6

0.6

0.6

0.6

1.0

—

0.6

0.6

0.6

—

1.0

1.0

—

—

DEST

FL 5

SS

FX3

SV

FH6

SF

SE

SL

SF

SJ

DEST

FA 17

FM1

SE

SS

SV

FM3

F

TYPE

AU

AT

AV

AV

AV

FSA

TERM

1

2

6

7

8

2

3

4

5

FSB

TERM

1

2

WIPERMOTOR

WIRE

600AK

SIZE

1.0

840

982

983

984

110K

1.0

1.0

1.0

1.0

1.0

839B

303C

1.0

1.0

DEST

SA

FP 7

FP 2

FP 3

FP 12

SP

SW

FA 47

840

832

833

805B

806B

984

836

803A

COLUMNSWITCH-RH

WIRE SIZE

110B 1.0

982

983

110A

—

839A

1.0

1.0

1.0

—

1.0

1.0

1.0

1.0

2.0

1.0

1.0

1.4

2.0

FN2

FW6

FA 35

SN

SM

FN5

FA 36

FV18

DEST

SP

FN3

FN4

SP

—

SW

855D

861D

835C

825C

411A

106B

—

—

FRONT WARNINGLIGHTS

WIRE SIZE

600EK 1.0

837D

830AG

805A

806H

804

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

1.0

—

—

DEST

SA

FA 37

SR

SN

SM

FV17

FA 38

FA 39

FY 3

SB

FA 40

FS1

—

—

WIRE

106B

106N

974

SPEEDO

SIZE

1.0

1.0

0.6

DEST

FR12

FA 46

FA 42

FP

TERM

1

2

3

4

7

8

9

5

6

10

11

12

13

14

4

5

6

7

8

FN

TERM

1

2

3

4

5

6

7

8

9

FR

TERM

1

2

3

10

11

12

13

14

FS

TERM

1

600MA

300A

—

—

0.6

0.6

—

—

SPEEDOILLUM

WIRE SIZE

830AK

600JA

0.6

0.6

SPEEDOILLUM

WIRE SIZE

830AU 0.6

600JB 0.6

SA

FV3

—

—

DEST

SR

SA

DEST

SR

SA

J,K

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AK

AK

R

TYPE

AF,AG

AF,AG

AH,AJ

AF,AG

AF,AG

AF,AG

AH,AJ

AF,AG

J,K

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AK

AF,AG

D,E

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AM

AL

S

TYPE

AN

AN

—

AL

AL

—

—

S

TYPE

AN

AN

FW

TERM

1

2

3

4

5

6

7

8

9

10

5

6

7

8

9

10

FX

TERM

1

2

3

4

3

4

5

7

8

10

17

FT

TERM

1

2

3

4

5

6

STEERMODESW

WIRE

820

SIZE

1.0

819A

823

819B

822

821

0.6

0.6

0.6

0.6

0.6

FU

TERM

1

2

3

4

5

6

BRAKEMODESW

WIRE SIZE

922G/933D

107S

853N

1.0

1.0

1.0

854J

853M

853L

1.0

1.0

1.0

FV

TERM

1

2

HAZARDSWITCH

WIRE

104

802

300

300A

SIZE

2.0

2.0

2.0

0.6

DEST

FA 29

FV25

FA 31

FS6

18

805

830AL

600DX

804

804A

803

803A

1.0

0.6

0.6

0.6

1.0

2.0

1.0

MAINLIGHTS

WIRE SIZE

SN

SR

SA

FR6

FK8

FA 26

FP 14

DEST

FZ2

FZ1

FZ6

FZ3

FZ5

FZ4

DEST

FA 9

SD

FC5

SD

FC1

FC2

DEST

311

828

1133A

127A

832

600DW

830AJ

2/4WDSELECT

WIRE

107D

922C

853G

854F

853H

600BR

830AH

2.0

2.0

1.0

2.0

1.4

0.6

0.6

SIZE

1.0

1.0

1.0

1.0

1.0

0.6

0.6

FA 30

FA 27

FA 18

FA 33

FP 8

SA

SR

DEST

SS

FJ3

SG

SJ

SG

SA

SR

N,P

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

N,P

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

T

TYPE

AR

AR

AS

AP

U

TYPE

U

TYPE

AR

AR

AP

AR

AR

AP

AP

AP

AP

AP

AP

AP

AP

AP

AP

AP

AR

AS

SA

WIRE

621

600L

600N

600AB

600AD

600AE

600AF

600AG

600AK

600BR

600DW

600DX

600EK

600JA

600JB

600MA

600DN

600DP

628

600AC

600LF

SB

WIRE

825B

825C

825D

FY

TERM

1

2

3

9

10

6

7

8

4

5

FOGLIGHT SWITCH

WIRE

868

835

835C

600N

830AV

SIZE

1.0

1.0

0.6

0.6

0.6

GA

TERM

1

2

3

4

8

9

10

5

6

7

7

8

9

4

5

6

10

FZ

TERM

1

2

3

BRAKELINKSKT

WIRE SIZE

107S 1.0

922G/933D

854J

1.0

1.0

853L

853M

853N

107L

107AF

—

—

1.0

1.0

1.0

1.0

1.0

BRAKELINKPIN

WIRE

—

933D

854G

853J

SIZE

—

1.0

853K

853F

—

1.0

1.0

1.0

1.0

—

—

922D

1855

—

1.0

1.0

DEST

FA 43

FA 44

FR9

SA

SR

DEST

—

SE

—

SV

FH7

SJ

SG

SG

SG

—

DEST

FU2

FU1

FU4

FU6

FU5

FU3

SS

SS

—

—

U

TYPE

AP

AR

AP

AP

G,H

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AK

AK

AE,AG

AE,AG

AK

AK

AE,AG

AE,AG

V,W

TYPE

AK

AE,AG

AE,AG

AE,AG

0.6

1.0

0.6

0.6

0.6

1.0

0.6

0.6

1.0

0.6

0.6

1.0

0.6

0.6

0.6

SIZE

6.0

1.0

0.6

0.6

0.6

0.6

FE10

FF5

FN1

FX7

FW7

FV10

FR1

FSA 2

FSB2

FS5

FA 50

FA 49

FM2

FD5

FF10

AX,AZ

DEST

FB1

FC8

FY 7

FH10

FE5

FD10

SIZE

1.0

0.6

1.0

AX,AY

DEST

FC7

FR10

FA 5

SIZE

1.0

1.0

1.0

1.0

1.0

1.0

SIZE

0.6

0.6

1.0

0.6

SIZE

0.6

0.6

0.6

SIZE

1.0

0.6

0.6

SIZE

1.0

1.0

1.0

1.0

SIZE

0.6

0.6

0.6

0.6

SIZE

0.6

0.6

1.0

SIZE

1.0

1.0

1.0

0.6

SIZE

1.0

1.0

1.0

1.0

SIZE

0.6

0.6

0.6

0.6

AX,AY

DEST

FA 51

FK7

FG5

FA 7

AX,AY

DEST

FH9

FX5

GA 3

FJ10

AX,AY

DEST

FK5

FK6

FE8

FD8

AX,AY

DEST

FL 13

FK3

FJ8

AX,AY

DEST

FK12

FP 11

FA 48

FR5

AX,AY

DEST

FJ6

FJ9

FA 22

FH8

AX,AY

DEST

FA 23

FH2

FJ7

GA 2

AX,AY

DEST

FA 14

GA 6

FX4

FX6

GA 4

GA 5

AX,AY

DEST

FL 9

FK1

FK2

AX,AY

DEST

FA 8

FT 2

FT 4

SK

WIRE

934B

934C

934D

934

SL

WIRE

858

858A

858K

SM

WIRE

806

806B

806D

806H

SH

WIRE

884

884A

884C

884D

SJ

WIRE

854E

854F

854G

854H

SG

WIRE

853

853F

853G

853H

853J

853K

SF

WIRE

818E

818F

818G

818H

SE

WIRE

933

933B

933C

933D

SC

WIRE

856

856A

856B

SD

WIRE

819

819A

819B

SN

WIRE

805

805A

805B

805D

SIZE

1.0

0.6

1.0

1.0

AX,AY

DEST

FV5

FR4

FP 10

FA 24

SIZE

2.0

1.0

1.0

2.0

1.0

SIZE

1.0

0.6

0.6

0.6

0.6

0.6

0.6

0.6

SIZE

1.0

1.0

1.0

0.6

1.0

1.0

0.6

0.6

0.6

1.0

1.0

0.6

SIZE

2.0

1.0

1.0

SIZE

0.6

0.6

0.6

SIZE

1.0

1.0

1.0

AX,AY

DEST

GA 9

FH4

FJ4

SIZE

1.0

1.0

1.0

AX,AY

DEST

FA 21

FP 6

FN7

721/10940_2

AX,AY

DEST

FA 12

FE2

FF7

FF8

FE6

AX,AY

DEST

FL 12

FF3

FK4

AX,AY

DEST

FA 34

FX2

FZ7

FL 7

FG1

FJ2

FZ8

FG3

FL 14

FH3

AX,AY

DEST

FA 20

FY 8

FSB1

FR3

FX8

FW8

FSA 1

FV8

AX,AY

DEST

FA 28

FP 4

FP 1

FL 11

FN6

107R

107AD

107AE

107AF

107AL

107A

107P

SS

WIRE

107

107D

107L

ST

WIRE

1858

1858A

1858B

1858C

1858D

SV

WIRE

922D

922E

922A

SW

WIRE

839

839A

839B

SU

WIRE

883

883B

883E

SR

WIRE

830C

830AV

830AU

830AG

830AH

830AJ

830AK

830AL

SP

WIRE

110

110A

110B

110H

110K

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section C

Electrics

151 — 3 Harness Data

Harness Drawing — Front Console, 6 speed Powershift (ShiftMaster) page 1 of 2 — CAD 721/10937 Issue 1

Electrics

Harness Data

Section C

151 — 3

FH

FK

FL

FM

FN

FP

FR

FS

FSA

Key to Connectors:

FA

FB

FC

FG

Bulkhead Plug

Front Cab Earth

Steer Mode Unit

Transmission Dump

Reverse Alarm

Brake Lights

Diodes

Column Switch — Powershift

Footbrake Switch

Wiper Motor

Column Switch — RH

Front Warning Lights

Speedometer

Speedometer Illumination

FT

FU

FV

FW

FX

FY

GA

GB

GD

GE

GF

GG

Steer Mode Switch

Brake Mode Switch

Hazard Switch

Main Lights

2/4WD Select

Fog Light Switch

Electronic Control Unit Plug

Electronic Control Unit Plug

Diagnostics Plug

Resistor Plug

Resistor Plug

Throttle Plug

9803/3280

Purchased from www.WorkshopManuals.co.uk

A721/10937_1

Issue 1

www.WorkshopManuals.co.uk

Section C

Electrics

151 — 4 Harness Data

Harness Drawing — Front Console, 6 speed Powershift (ShiftMaster) page 2 of 2 — CAD 721/10937 Issue 1

8

9

7

6

10

FH

TERM

1

2

3

4

5

9

10

6

7

8

FC

TERM

1

2

3

6

7

8

4

5

FG

TERM

1

2

3

4

5

26

27

28

29

30

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

13

8

9

6

7

FA

TERM

1

2

3

4

5

SL

SE

SN

FV2

FV18

FW3

SP

FV1

FW2

GC18

GC23

GC4

SG

FW4

GC15

SR

SW

GB30

GC24

FG7

GC20

GC6

FG5

SD

FT 1

DEST

FC3

SF

FC4

FC6

SB

818/858

933

805D

802

803

828

1866

126A

134

1865

830C

839

110

104

311

815C

1860

1858

1862

853

1863

BULKHAEDPLUG

WIRE SIZE

824B

810E

1.0

1.0

1.0

826B

845

825B

1.0

1.0

1861

934B

819

820

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

2.0

2.0

1.0

1.0

1.0

1.0

2.0

2.0

2.0

2.0

FB

TERM

1

FRONT CABEAR TH

WIRE

621

SIZE

4.0

DEST

SA

STEERMODEUNIT

WIRE

822

821

824B

826B

823

845

825D

600L

1873

107AL

SIZE

0.6

0.6

1.0

1.0

1.0

1.0

1.0

1.0

WIRE

107AD

TRANSDUMP

SIZE

1.0

1.0

0.6

DEST

FT 5

FT 6

FA 1

FA 3

FT 3

FA 4

SB

SA

DEST

SS

GB37

SS

934B

107V

1.0

REV ALARM

1.0

1858

808F

—

600JX

1.0

0.6

—

0.6

WIRE

BRAKELIGHTS

SIZE

126C

933B

126D

1.0

1.0

0.6

FA 7

SS

FA 12

SJ

—

SA

DEST

SG

SE

SG

877 FM3

933D

—

909

1800

600AB

0.6

2WB

1.0

—

1.0

1.0

0.6

SE

FU3

—

GB20

SA

AA

AA

AA

AB

AA

AA

AA

AA

AB

AB

AB

AB

AB

AA

AA

AA

AA

AA

AA

AA

AA

TYPE

AA

AA

AA

AA

AA

AA

AA

AA

AA

—

TYPE

C

F

TYPE

AS

AS

AV

D,E

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AV

AS

—

AV

AV

AV

F

TYPE

AS

AS

AV

—

AV

AS

AS

AV

—

AV

56

57

58

59

60

52

53

54

55

48

49

50

51

44

45

46

47

40

41

42

43

36

37

38

39

TERM

31

32

33

34

35

FK

TERM

1

2

402

403

404

405

406

135

136

—

—

835

992

106N

303K

806D

600DP

600DN

1864

836

837D

855D

861D

411A

405A

974

868

WIRE

300

814

127A

107

833

WIRE

804A

806

1.0

1.0

—

—

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

2.0

0.6

1.0

1.0

SIZE

2.0

2.0

2.0

2.0

2.0

DIODES

SIZE

1.0

1.0

GB23

GB35

GC21

GB13

GB15

SC

GB2

—

—

FY 3

GB39

FS1

ST

SM

SA

SA

GC12

FP 13

FR2

FR7

FR8

SU

GC1 1

GC3

FY 2

DEST

FV3

FL 8

FW5

SS

FP 9

DEST

FV17

SM

AA

AA

AC

AC

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

AA

A,B

TYPE

AB

AB

AB

AB

AB

AB

AA

AA

AA

BN,BP

TYPE

AF,AG

AF,AG

FM

TERM

1

2

3

FL

TERM

1

2

3

4

5

8

9

10

6

7

11

12

13

14

FN

TERM

5

6

7

8

3

4

1

2

FOOTBRAKESW

WIRE

126

628

877

809

857

810

135B

814

856

808

110H

883

858

135C

SIZE

0.6

0.6

0.6

COLUMNSWITCH-P/SHIFT

WIRE SIZE

—

—

—

—

—

—

2.0

0.6

0.6

2.0

0.6

0.6

0.6

1.0

0.6

1.0

0.6

WIPERMOT OR

WIRE SIZE

1.0

600AK

840

982

1.0

1.0

983

984

303C

839B

—

1.0

1.0

1.0

1.0

—

DEST

SG

SA

FH5

SJ

SP

GB18

SL

SC

DEST

SA

FP 7

FP 2

FP 3

FP 12

ST

SW

—

DEST

—

—

—

GB7

GB27

SF

SC

FA 32

GB8

J,K

TYPE

AK

AK

AK

AF,AG

AF,AG

AF,AG

AF,AG

AH,AJ

AF,AG

AF,AG

AH,AJ

AF,AG

AF,AG

AF,AG

D,E

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AK

L,M

TYPE

AD

AD

AD

Electrics

Harness Data

Section C

151 — 4

832

833

805B

806B

984

836

803A

COLUMNSWITCH-RH

WIRE

110B

SIZE

1.0

982

983

1.0

1.0

110A

—

839A

840 1.0

1.4

2.0

1.0

1.0

1.0

2.0

1.0

1.0

—

1.0

FA 35

SN

SM

FN5

FA 36

FV18

DEST

SP

FN3

FN4

SP

—

SW

FN2

FW6

FRONT WARNINGLIGHTS

WIRE

600EK

837D

SIZE

1.0

1.0

830AG

805A

806H

804

855D

861D

835C

0.6

1.0

1.0

1.0

1.0

1.0

0.6

825C

411C

106B

—

—

0.6

1.0

1.0

—

—

DEST

SA

FA 37

SR

SN

SM

FV17

FA 38

FA 39

FY 3

SB

SU

FS1

—

—

WIRE

106B

106N

974

SPEEDO

SIZE

1.0

1.0

0.6

DEST

FR12

FA 46

GB14

FR

TERM

1

2

5

6

3

4

7

8

9

10

11

12

13

14

FS

TERM

1

10

11

12

13

14

8

9

6

7

FP

TERM

1

2

3

4

5

FSB

TERM

1

2

FU

TERM

1

5

6

2

3

4

FT

TERM

1

2

3

4

5

6

FSA

TERM

1

2

2

3

4

5

6

600MA

300A

0.6

0.6

SPEEDOILLUM

WIRE SIZE

830AK

600JA

0.6

0.6

SPEEDOILLUM

WIRE

830AU

600JB

SIZE

0.6

0.6

SA

FV3

DEST

SR

SA

DEST

SR

SA

WIRE

STEERMODESW

SIZE

820

819A

1.0

0.6

823

819B

822

821

0.6

0.6

0.6

0.6

BRAKEMODESW

WIRE

—

SIZE

—

107S

909

107L

—

922G

1.0

1.0

1.0

—

1.0

DEST

FA 9

SD

FC5

SD

FC1

FC2

DEST

—

SS

FH8

SS

FX3

—

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AK

AK

J,K

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AH,AJ

AH,AJ

AF,AG

AF,AG

AF,AG

AH,AJ

AF,AG

J,K

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AK

AF,AG

R

TYPE

AM

AL

S

TYPE

AN

AN

N,P

TYPE

AK

AF,AG

AF,AG

AF,AG

AK

AF,AG

N,P

TYPE

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AF,AG

AL

AL

S

TYPE

AN

AN

FV

TERM

1

2

3

7

8

10

4

5

17

18

FY

TERM

2

6

7

8

4

5

3

7

8

GA

TERM

1

2

5

6

7

3

4

10

11

8

9

12

13

14

18

19

20

21

22

23

24

15

16

17

FX

TERM

1

2

3

6

7

8

3

4

5

FW

TERM

1

2

300A

—

805

—

830AL

HAZARDSWITCH

WIRE SIZE

104

802

300

2.0

2.0

2.0

0.6

—

1.0

—

600DX

804

804A

803

803A

0.6

0.6

1.0

1.0

2.0

1.0

DEST

FA 29

FA 25

FA 31

FS6

—

SN

—

SR

SA

FR6

FK1

FA 26

FP 14

WIRE

—

MAINLIGHTS

SIZE

—

311

828

134

127A

832

600DW

830AJ

2.0

2.0

1.0

2.0

1.4

0.6

0.6

DEST

—

FA 30

FA 27

FA 18

FA 33

FP 8

SA

SR

AS

2/4WDSELECT

WIRE SIZE

—

107D

922

922G

—

1.0

1.0

1.0

—

—

—

600BR

830AH

1.0

1.0

—

—

—

FOGLIGHT SWITCH

WIRE

868

835

SIZE

1.0

1.0

0.6

835C

600N

830AV

0.6

0.6

ECUII’B’PLUG

WIRE SIZE DEST

DEST

FA 43

FA 44

FR9

SA

SR

DEST

—

SS

GB40

FU6

—

—

—

SA

SR

974

1866

1861

405A

1864

600MH

1865

853

1862

404

1863

1860

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

FA 42

FA 16

FA 6

FA 41

FA 51

SA

FA 19

FA 14

FA 13

FA 58

FA 15

FA 11

AP

AP

AC

AC

AC

V

AC

V

V

V

AC

AC

V

AC

V

V

AC

V

V

G

TYPE

AC

AC

V

V

AC

V

AC

U

TYPE

AP

—

—

—

AP

AP

AR

U

TYPE

—

AP

AR

U

TYPE

—

AR

AR

AP

AR

AR

AP

AP

T

TYPE

AR

AR

AS

—

AR

—

AP

AP

AR

ECUII’A’PLUG

WIRE

135A

136

107X

500

809

856

405

974

406

501

858A

883

991

1800

402

411B

600MJ

857

810D

815C

SIZE

0.6

1.0

1.0

1.0

0.6

1.0

1.0

0.6

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

DEST

SC

FA 53

SS

SX

FL 4

FL 9

FA 59

FS2

FA 60

SZ

SL

FL 12

GG2

FH9

FA 56

SU

SA

FL 5

SF

FA 10

403

600MK

1873

808G

992

922

DIAGNOSTICSPLUG

WIRE

600ML

SIZE

303L

1.0

1.0

500D

501D

1.0

1.0

1.0

1.0

1.0

0.6

1.0

1.0

FA 57

SA

FG2

SJ

FA 45

FX3

DEST

SA

ST

SY

TA

RESISTORPLUG

WIRE SIZE

500A

501A

1.0

1.0

RESISTORPLUG

WIRE

500C

501C

SIZE

1.0

1.0

DEST

SX

SZ

DEST

SY

TA

THROTTLESWITCH

WIRE

107T

SIZE

1.0

991 1.0

DEST

SS

GB19

AU,BH

TYPE

AD

AD

AU,BH

TYPE

AD

AD

BL,BM

TYPE

AF,AG

AF,AG

AC

V

AC

V

V

V

V

V

AC

V

V

V

V

V

V

AC

AC

AC

V

V

AC

V

V

H

TYPE

V

V

AC

V

AC

AC

AC

V

V

AC

V

AC

AC

V

V

V

V

W

TYPE

AB

AB

AB

AB

—

—

—

—

—

GE

TERM

1

2

GF

TERM

1

2

GG

TERM

1

2

33

34

35

36

29

30

31

32

37

38

39

40

22

23

24

25

26

27

28

18

19

20

21

10

11

12

13

8

9

6

7

GB

TERM

1

2

3

4

5

14

15

16

17

GD

TERM

C

D

A

B

G

H

J

E

F

SIZE

1.0

0.6

1.0

SIZE

1.0

0.6

0.6

0.6

SIZE

1.0

0.6

0.6

SIZE

1.0

1.0

1.0

SIZE

1.0

0.6

1.0

SIZE

0.6

1.0

1.0

0.6

AX,AY

DEST

FA 52

GB1

FL 7

FL 14

AX,AY

DEST

FA 8

FT 2

FT 4

AX,AZ

DEST

FB1

FC8

FY 7

FH10

FN1

FX7

FW7

FV10

FR1

FSA2

FSB2

FS5

FA 50

FA 49

FM2

GC13

GB26

GB36

GD A

FG10

AX,AY

DEST

FA 5

FR10

FC7

AX,AY

DEST

FA 23

FH2

FH6

AX,AY

DEST

FL 6

GB28

FA 2

AX,AY

DEST

FM1

FA 17

FH1

FH3

1.0

0.6

1.0

1.0

0.6

0.6

0.6

1.0

0.6

0.6

0.6

1.0

SIZE

4.0

1.0

0.6

0.6

1.0

1.0

1.0

0.6

SC

WIRE

135

135A

135B

135C

SD

WIRE

819

819A

819B

SA

WIRE

621

600L

600N

600AB

600AK

600BR

600DW

600DX

600EK

600JA

600JB

600MA

600DN

600DP

628

600MH

600MJ

600MK

600ML

600JX

SB

WIRE

825B

825C

825D

SE

WIRE

933

933B

933D

SF

WIRE

810

810D

810E

SG

WIRE

126

126A

126C

126D

SJ

WIRE

808

808F

808G

SL

WIRE

858

858A

818/858

SIZE

0.6

0.6

0.6

SIZE

1.0

1.0

1.0

AX,AY

DEST

FL 10

FG8

GB38

AX,AY

DEST

FL 13

GB17

FA 22

SIZE

1.0

0.6

0.6

0.6

0.6

0.6

0.6

0.6

0.6

1.0

1.0

1.0

1.0

0.6

SIZE

2.0

1.0

1.0

SIZE

1.0

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

1.0

SIZE

2.0

1.0

1.0

2.0

AX,AY

DEST

FA 20

FY 8

FSB1

FR3

FX8

FW8

FSA1

FV8

AX,AY

DEST

FA 28

FP 4

FP 1

FL 11

AX,AY

DEST

FA 34

FX2

FU4

FU2

GG1

FG6

GB4

FG1

FG3

AX,AY

DEST

FV5

FR4

FP 10

FA 24

AX,AY

DEST

FK2

FP 11

FA 48

FR5

SR

WIRE

830C

830AV

830AU

830AG

830AH

830AJ

830AK

830AL

SS

WIRE

107

107D

107L

107S

107T

107V

107X

107AD

107AL

SM

WIRE

806

806B

806D

806H

SN

WIRE

805

805A

805B

805D

SP

WIRE

110

110A

110B

110H

SIZE

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

AX,AY

DEST

FN6

FA 47

GDB

AX,AY

DEST

FA 40

GB25

FR1 1

SIZE

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

AX,AY

DEST

SX

GF1

GDC

AX,AY

DEST

GB16

GE2

TA

AX,AY

DEST

SZ

GF2

GDD

721/10937_2

AX,AY

DEST

FA 21

FP 6

FN7

AX,AY

DEST

GB6

GE1

SY

SY

WIRE

500B

500C

500D

SZ

WIRE

501

501A

501B

TA

WIRE

501B

501C

501D

SW

WIRE

839

839A

839B

SX

WIRE

500

500A

500B

SU

WIRE

411A

411B

411C

ST

WIRE

303C

303K

303L

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section C

Electrics

153 — 1 Harness Data

Harness Drawing — Side Console, page 1 of 4

*

— CAD 721/10936 Issue 1

(Machines up to serial no. 933756)

Section C

153 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

721/10936_1

Issue 2*

www.WorkshopManuals.co.uk

Section C

Electrics

153 — 2 Harness Data

Harness Drawing — Side Console, page 2 of 4

*

— CAD 721/10936 Issue 1

(Machines up to serial no. 933756)

Electrics

Harness Data

Key to Connectors:

CX

CXA

CY

CYA

CYB

CZ

DA

DB

DBA

DC

DD

DE

DF

DG

CF

CG

CH

CJ

CK

CL

CB

CCA

CCB

CCC

CD

CE

CM

Cab Link

Fuse Box A

Fuse Box B

Fuse Box C

Ignition 1

Ignition 2

Start Inhibit

Buzzer

Direct Relay

Front Worklingt Relay

Rear Worklight Relay

Engine Run Relay

Lights

Rear Horn

Park Brake Relay

Blank CN

CP

CR

CS

HSC Relay

Jaw Bucket Relay

Hammer

Cab Roof

Headliner

CT

CU

CV

CW

Rear Cab Bulkhead

Ignition Switch

Instrument Panel

Fuel Gauge

CWA Fuel Gauge Illumination

Water Temperature Gauge

Water Temperature Illumination

Tachometer

Tachometer Illumination

Tachometer Illumination

Radio Cassette

Radio Speaker

Heater Controls

Heater Jumper

Front Worklight Switch

Beacon Switch

HSE Switch

SRS Switch

Shovel Reset

DH

DJ

DK

DL

DM

DN

DP

DPA

DR

DS

Rear Worklight Switch

Rear Wash/Wipe Switch

Auxiliary Hydraulic Switch

Hydraclamp Switch

Rear Wiper

Worklight Diode

Worklight Connector

Worklight Connector

Earth Ring

Heater Unit

DT

DV

DW

DX

DY

Diode Gate

PSS Buzzer

Park Brake

Cigar Lighter

Dallas Key

DZ A/C Compressor Relay

Blank

EA Immobiliser

EAB Link

Section C

153 — 2

721/10936_2

Issue 2* 9803/3280

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section C

Electrics

153 — 3 Harness Data

Harness Drawing — Side Console, page 3 of 4 — CAD 721/10936 Issue 1

(Machines up to serial no. 933756)

Electrics

Section C

153 — 3

9803/3280

721/10936_3

Purchased from www.WorkshopManuals.co.uk

Issue 2*

www.WorkshopManuals.co.uk

Section C

153 — 4

Electrics

Harness Data

Harness Drawing — Side Console, page 4 of 4 — CAD 721/10936 Issue 1

(Machines up to serial no. 933756)

Electrics

Harness Data

Section C

153 — 4

9803/3280

Purchased from www.WorkshopManuals.co.uk

721/10936_4

Issue 2*

www.WorkshopManuals.co.uk

Section C

Electrics

153 — 5 Harness Data

Harness Drawing — Side Console, page 1 of 5 — CAD 721/10970 Issue 2

(Machines from serial no. 933757)

Electrics

Harness Data

Section C

153 — 5

9803/3280

Purchased from www.WorkshopManuals.co.uk

721/10970_1

Issue 1

Section C

153 — 6

www.WorkshopManuals.co.uk

Electrics

Harness Data

Section C

153 — 6

Harness Drawing — Side Console, page 2 of 5 — CAD 721/10970 Issue 2

(Machines from serial no. 933757)

Key to Connectors:

CK

CL

CM

CN

CP

CR

CS

CU

DB

DBA

CE

CF

CG

CH

CJ

CA

CCA

CCB

CCC

CD

DP

DPA

DR1

DR2

DR3

DT

DV1

DV2

DW

DZ

Main Frame Plug

Fusebox A

Fusebox B

Fusebox C

Ignition 1

Ignition 2

Start Inhibit

Buzzer

Direction Indicator Relay

Front Work Light Relay

Rear Work Light Relay

Engine Run Relay

Rear Horn

Hydraulic Speed Control Relay

Jaw Bucket Relay

Cab Roof

Headliner

Ignition Switch (CU2)

Heater Controls

Heater Jumper

Work Light

Work Light link

Earth 1

Earth 2

Earth 3

Diode Gate

Auxiliary Buzzer 1

Auxiliary Buzzer 2

Park Brake

Air Conditioning Compressor Relay

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section C

153 — 7

www.WorkshopManuals.co.uk

Electrics

Harness Data

Section C

153 — 7

Harness Drawing — Side Console, page 3 of 5 — CAD 721/10970 Issue 2

(Machines from serial no. 933757)

Key to Connectors:

DK

DL

DM

DN

DS

DX

DY

EA

EAB

EB

EBA

DE

DF

DG

DH

DJ

CYB

CZ

DA

DC

DD

CB

CU

CV

CW

Cab Link

Ignition Switch (CU1)

Instrument Panel

Fuel Gauge

CWA Fuel Gauge Illium

CX Water Temperature Gauge

CXA

CY

CYA

Water Temperature Illium

Tachometer

Tachometer Illium A

Tachometer Illium B

Radio Cassette

Radio Speaker

Front Work Light Switch

Beacon Switch

Hydraulic Speed Control Switch

Smooth Ride System Switch

Shovel Reset

Rear Work Light Switch

Rear Wash/Wipe Switch

Auxiliary Hydraulic Switch

Hydraclamp Switch

Rear Wiper

Work Light Diode

Heater Unit

Cigar Lighter

Dallas Key

Immobiliser

Immobiliser Link

Exciter Diode

Exciter Link

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

www.WorkshopManuals.co.uk

Section C

Electrics

153 — 8

Harness Data

Harness Drawing — Side Console, page 4 of 5 — CAD 721/10970 Issue 2

(Machines from serial no. 933757)

Electrics

Harness Data

Section C

153 — 8

9803/3280

Purchased from www.WorkshopManuals.co.uk

721/10970_2

Issue 1

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Cab Roof (USA only) page 1 of 2 — CAD 721/10966 Issue 1

Purchased from www.WorkshopManuals.co.uk

721/10966_1

www.WorkshopManuals.co.uk

Harness Drawing — Cab Roof (USA only) page 2 of 2 — CAD 721/10966 Issue 1

Key to Connectors:

C40

C47

C50

C55

C60

C65

C70

C75

C80

S5

C5

C10

C15

C20

C25

C30

C35

S15

S20

S21

S22

S23

S24

S30

S40

S45

S55

S60

S65

LH Worklight

Beacon Socket

LH Front Indicators

RH Worklight

LH Headlights

RH Headlights

RH Front Indicators

Cab Horn

Earth

RH Rear Lights

RH RR/Out Worklight

RH RR/In Worklight

LH RR/In Worklight

LH RR/Out Worklight

LH Rear Lights

Auxiliary Beacon Socket

FWL O

FWL 1

Beacon

Dip

HD.L

Earth

RH Indicators

LH Indicators

RWL O

Brake

RWL 1

LH SL

RH SL

721/10966_2

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Cab Roof (not USA) page 1 of 2 — CAD 721/10965 Issue 1

RH HEADLIGHTS

BEACON SOCKET

RH WORKLIGHT

LH WORKLIGHT

EARTH

10 11 12

CAB HRN

AUX BEACON

SOCKET

C80

200

LH HEADLIGHTS

Purchased from www.WorkshopManuals.co.uk

C55

C60

C65

C70

721/10965_1

www.WorkshopManuals.co.uk

Harness Drawing — Cab Roof (not USA) page 2 of 2 — CAD 721/10965 Issue 1

Key to Connectors:

C55

C60

C65

C70

C80

S5

S15

S20

S21

S22

C5

C10

C20

C25

C30

C40

C47

S23

S24

S40

LH Worklight

Beacon Socket

RH Worklight

LH Headlights

RH Headlights

Cab Horn

Earth

RH RR/Out Worklight

RH RR/In Worklight

LH RR/In Worklight

LH RR/Out Worklight

Auxiliary Beacon Socket

FWL O

FWL 1

Beacon

Dip

HD.L

Earth

RH Indicators

RWL

C30 5

C25 1

C40 8

721/10965_2

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Interior Light, Radio Speakers page 1 of 1 — CAD 721/11050 Issue 1

LS

TERM

1

2

WIRE

LH SPEAKER

SIZE

859

601

0.6

0.6

DEST

—

TYPE

G,H

E,F

RS

TERM

1

2

WIRE

RH SPEAKER

SIZE

860

602

0.6

0.6

DEST

—

TYPE

G,H

E,F

IL

TERM

1

2

INTERIOR LIGHT

WIRE SIZE

303F

600EJ

1.0

1.0

100

DEST

—

TYPE

G,H

G,H

Connector Key

CP Cab Panel

IL

LH

RH

Interior Light

Left Hand Speaker

Right Hand Speaker

CP

TERM

1

2

5

6

3

4

WIRE

CAB PANEL

SIZE

303F

859

1.0

0.6

860

600EJ

601

602

0.6

1.0

0.6

0.6

DEST

LS1

RS1

LS2

RS2

A,B

TYPE

C,D

C,D

C,D

C,D

C,D

C,D

721/11050_1

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Steer Controls, page 1 of 1- CAD 721/10968 Issue 1

Key to Connectors:

MA

MD

ME

MF

SA

SM

2WS

4WS

Cab Connector

Rear Proximity Switch

Steer Mode Feed

Steer Mode Feed

Purchased from www.WorkshopManuals.co.uk

721/10968_1

www.WorkshopManuals.co.uk

Harness Drawing — Steer Controls, page 1 of 1 — CAD 721/10967 Issue 1

Key to Connectors:

MA

MB

MC

MD

ME

MF

SA

2WS

4WS com

Crab

4WS

Cab Connector

Rear Proximity Switch

Steer Mode Feed

DEST

DA

Purchased from www.WorkshopManuals.co.uk

1.0

1.0

721/10967_1

www.WorkshopManuals.co.uk

Harness Drawing — Transmission, page 1 of 2 — CAD 721/10943 Issue 1

Key to Connectors:

LE

SB

SC

SD

LA

LB

LC

LD

Front Console Harness

Side Console Harness

Gearbox

Transmission Oil Temperature Switch

Kickdown Switch

Transmission Fused Splice

Earth Splice

Transmission Oil P Splice

Purchased from www.WorkshopManuals.co.uk

13

37

49

721/10943_1

www.WorkshopManuals.co.uk

Harness Drawing — Transmission, page 2 of 2 — CAD 721/10943 Issue 1

721/10943_2

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Transmission, page 1 of 2 — CAD 721/10942 Issue 1

Key to Connectors:

LA

LB

LC

LD

SA

SB

SC

SD

Front Console Harness

Side Console Harness

Gearbox

Transmission Oil Temperature Switch

Dump Splice

Transmission Feed Splice

Earth Splice

Transmission OIl P Splice

CELLS 1-30 CELLS 1-30

12

24

30

36

48

60

FRONT CONSOLE

HARNESS

13

25

31

37

49

13mm WIDE (NOM)

RED TAPE (2 POSN)

CELLS 31-60

DATUM

CELLS 31-60

TRANSMISSION

OIL TEMP SW

12 11 10

GEARBO

HARNESS

Purchased from www.WorkshopManuals.co.uk

12

24

30

36

48

60

SIDE CONSOLE

HARNESS

13

37

49

721/10942_1

www.WorkshopManuals.co.uk

Harness Drawing — Transmission, page 2 of 2 — CAD 721/10942 Issue 1

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Transmission, page 1 of 2 — CAD 721/10941 Issue 1

721/10941_1

HSG ID

C20

C30

C40

C50

C60

C70

C80

C90

SOLENOID IDENTIFICATION

FUNCTION

FORWARD HIGH

FORWARD LOW

MAINSHAFT

LAYSHFT

REVERSE LOW

REVERSE HIGH

2/4 WHEEL DRIVE

6TH SPEED

ID CHAR

150

120

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Transmission —

*

Powershift 6 speed, page 2 of 2 — CAD 721/10941 Issue 1

Key to Connectors:

C10

C15

C17

C20

C30

C40

C50

C60

C70

C80

C90

Cab Panel

XMSN Oil Press Switch

Speed Sensor

Forward High

Forward Low

Main Shaft

Lay Shaft

Reverse Low

Reverse High

4WD

6th Speed

C15

TERM

1

2

C17

TERM

1

2

3

C20

TERM

1

2

C10

TERM

1

2

3

4

5

6

9

10

11

12

7

8

C30

TERM

1

2

WIRE

600Z

CAB PANEL

SIZE

405

1862

2.0

1.0

1.0

1861

853

107AK

974

1860

1.0

1.0

1.0

1.0

1863

1866

1865

1864

1.0

1.0

1.0

1.0

1.0

XMSN OIL PRESS SW

WIRE SIZE

405

600BU

1.0

1.0

DEST

C10 2

SA

SPEED SENSOR

WIRE

600HV

SIZE

1.0

974

107AK

1.0

1.0

DEST

SA

C10 7

C10 6

FORWARD HIGH

WIRE SIZE

1861

600BS

1.0

1.0

DEST

C10 4

SA

C17 3

C17 2

C30 1

C60 1

C50 1

C40 1

C90 1

DEST

SA

C15 1

C70 1

C20 1

C80 1

FORWARD LOW

WIRE SIZE

1860

600BX

1.0

1.0

DEST

C10 8

SA

C,D

TYPE

H

H

E,F

TYPE

H

H

H

C,D

TYPE

H

H

H

H

H

H

H

A,B

TYPE

G

H

H

H

H

H

H

C,D

TYPE

H

H

C70

TERM

1

2

C80

TERM

1

2

C90

TERM

1

2

C40

TERM

1

2

C50

TERM

1

2

C60

TERM

1

2

WIRE

MAIN SHAFT

SIZE

1865

600BZ

1.0

1.0

DEST

C10 11

SA

WIRE

1866

600BY

LAY SHAFT

SIZE

1.0

1.0

DEST

C10 10

SA

REVERSE LOW

WIRE SIZE

1863

600CA

1.0

1.0

DEST

C10 9

SA

REVERSE HIGH

WIRE

1862

600BT

SIZE

1.0

1.0

DEST

C10 3

SA

WIRE

853

600CB

4 W/D

SIZE

1.0

1.0

DEST

C10 5

SA

WIRE

1864

600ME

6TH SPEED

SIZE

1.0

1.0

DEST

C10 12

SA

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

SA

WIRE

600Z

600BY

600BZ

600CB

600BS

600BX

600CA

600BT

600BU

600HV

600ME

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

SIZE

2.0

1.0

1.0

K,L

DEST

C10 1

C50 2

C40 2

C80 2

C20 2

C30 2

C60 2

C70 2

C15 2

C17 1

C90 2

721/10941_2

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Transmission — Sychro Shuttle, page 1 of 1 — CAD 721/10938 Issue 2

*

Key to Connectors:

GA

GB

GC

GD

GE

GF

Cab Panel

Forward Solenoid

Reverse Solenoid

Transmission Dump Switch

4WD

XMSN Oil Pressure Switch

GB

TERM

1

2

GC

TERM

1

2

GA

TERM

1

2

3

6

7

4

5

8

9

10

11

12

—

—

—

—

WIRE

CAB PANEL

SIZE

600Z

405

811

2.0

1.0

1.0

812

853

—

—

934B

—

1.0

—

—

—

—

1.0

1.0

—

FORWARD SOLENOID

WIRE SIZE DEST

812

600BS

1.0

1.0

GA 4

SA

—

—

—

—

—

GD A

DEST

SA

GF 1

GC 1

GB 1

GE 1

—

REVERSE SOLENOID

WIRE

811

600BT

SIZE

1.0

1.0

DEST

GA 3

SA

E,F

TYPE

C

C

E,F

TYPE

C

C

D

D

D

D

D

D

C

A,B

TYPE

C

C

C

C

C

SA

WIRE

600Z

600FL

600CB

600BS

600BT

600BU

GD

TERM

A

B

GE

TERM

1

2

GF

TERM

1

2

TRANS DUMP SW

WIRE SIZE

934B

600FL

1.0

1.0

DEST

GA 12

SA

WIRE

853

600CB

4 W/D

SIZE

1.0

1.0

DEST

GA 5

SA

XMSN OIL PRESS SW

WIRE SIZE

405

600BU

1.0

1.0

DEST

GA 2

SA

SIZE

2.0

1.0

1.0

1.0

1.0

1.0

M,N

DEST

GA 1

GD B

GE 2

GB 2

GC 2

GF 2

721/10938_1

G

TYPE

H,J

H,J

E,F

TYPE

C

C

E,F

TYPE

C

C

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Harness Drawing — Transmission — Powershift 4 speed, page 1 of 1 — CAD 721/10939 Issue 1

Solenoid Identification

Function

SOLENOID IDENTIFICATION

C40

C50

C50

C60

MAINSHAFT

Layshaft

LAYSHAFT

Identification

I

E

F

G

H

J

K

IDCHAR

E

J

K

I

H

F

G

C20

TERM

1

2

C30

TERM

1

2

12

C15

TERM

1

2

C10

TERM

1

2

9

10

6

7

8

3

4

5

WIRE

CABP ANEL

SIZE

600Z

405

812

853

2.0

1.0

1.0

1.0

1.0

848

849

850

851

—

1.0

1.0

1.0

1.0

—

C301

C601

C501

C401

—

XMSNOIL PRESSSW

WIRE SIZE

405

600BU

1.0

1.0

DEST

C102

SA

FORWARDHIGH

WIRE SIZE

812

600BS

1.0

1.0

DEST

C104

SA

FORWARDLOW

WIRE

848

600BX

SIZE

1.0

1.0

DEST

C108

SA

DEST

SA

C151

C701

C201

C801

C,D

TYPE

H

H

C,D

TYPE

H

H

A,B

TYPE

G

H

H

H

H

J

J

H

H

H

H

J

C,D

TYPE

H

H

C40

TERM

1

2

C50

TERM

1

2

C60

TERM

1

2

C70

TERM

1

2

C80

TERM

1

2

WIRE

MAINSHAFT

SIZE

851

600BZ

1.0

1.0

DEST

SA

WIRE

850

600BY

SIZE

1.0

1.0

DEST

C1010

SA

REVERSELOW

WIRE SIZE

849

600CA

1.0

1.0

DEST

C109

SA

REVERSEHIGH

WIRE

600BT

SIZE

1.0

1.0

DEST

C103

SA

WIRE

853

600CB

4W/D

SIZE

1.0

1.0

DEST

C105

SA

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

C,D

TYPE

H

H

SA

WIRE

600Z

600BY

600BZ

600CB

600BS

600BX

600CA

600BT

600BU

1.0

1.0

1.0

1.0

1.0

1.0

SIZE

2.0

1.0

1.0

C802

C202

C302

C602

C702

C152

K,L

DEST

C101

C502

C402

Purchased from www.WorkshopManuals.co.uk

721/10939

www.WorkshopManuals.co.uk

Harness Drawing — Engine Mainframe, page 1 of 2 — CAD 721/10935 Issue 2

*

Purchased from www.WorkshopManuals.co.uk

721/10935_1

www.WorkshopManuals.co.uk

Harness Drawing — Engine Mainframe, page 2 of 2 — CAD 721/10935 Issue 2

*

Key to Connectors:

MR

MS

MT

MU

MV

MK

ML

MM

MN

MP

MA

MB

MC

MD

ME

MF

MG

MH

MJ

NC

ND

NF

NG

NH

MW

MX

MY

NA

NB

NU

NK

Engine Oil Pressure

Earth

Front Proximity Switch

Front Horn

Starter

Waxstat

ESOS

Alternator D+

Alternator PWR

Alternator W

Water Temperature Sender

Air Conditioning

Water Temperature Switch

Front wash Pump

Rear Wash Pump

Start Solenoid

Air Filter

Thermostart

SRS

SRS

Primary Fuse 1 (Grey)

Primary Fuse 2 (Blue)

HSE Solenoid

Shovel Reset

Fuel Sender

Reset Switch

HSC Switch

Dump Switch

Cab Panel — Bulk Head

Earth

Seat Connector

AR,AS

TYPE

BF

BF

BF

—

TYPE

AM,B

—

TYPE

V,W

—

TYPE

V,W

—

TYPE

X,B

—

TYPE

Y,AN

C,D

TYPE

BB

BB

Z

TYPE

AB,AC

C,D

TYPE

BB

BB

J,K

TYPE

L,M

L,M

AU,AV

TYPE

BB

BB

BB

J,K

TYPE

M,N

M,N

C,D

TYPE

BB

BB

—

TYPE

A,AN

ENG OIL PRESS

WIRE

403

600MC

SIZE

1.0

1.0

WIRE

600A

EARTH

SIZE

4.0

DEST

NH 3

SA

DEST

SA

FRONT PROX SW

WIRE SIZE

819

600BW

109

1.0

1.0

1.0

DEST

NH 4

SA

NH 41

WIRE

814

600B

FRONT HORN

SIZE

2.0

2.0

DEST

NH 20

SA

WIRE

200J

STARTER

SIZE

16.0

WIRE

105A

WAXSTAT

SIZE

1.0

WIRE

105B

600

513

ESOS

SIZE

1.0

1.0

1.0

DEST

MJ 1

DEST

SB

DEST

SB

SA

NH 44

ALTERNATOR D+

WIRE

407

SIZE

1.0

DEST

NH 38

ALTERNATOR PWR

WIRE SIZE

200J 16.0

DEST

ME 1

ALTERNATOR W

WIRE SIZE

412 1.0

DEST

NH 47

MC

TERM

A

B

C

MD

TERM

1

2

MA

TERM

1

2

MB

TERM

1

MG

TERM

1

2

3

MH

TERM

1

ME

TERM

1

MF

TERM

1

MJ

TERM

1

MK

TERM

1

MN

TERM

1

2

MP

TERM

1

2

ML

TERM

1

2

MM

TERM

1

WATER TEMP SENDER

WIRE

409

SIZE

1.0

DEST

NH 46

600JT 1.0

SA

WIRE

903

AIR CON

SIZE

1.0

DEST

NH 9

WATER TEMP SW

WIRE

406

600CK

SIZE

1.0

1.0

DEST

NH 11

SA

FRONT WASH PUMP

WIRE

839

600BG

SIZE

1.0

1.0

DEST

NH 48

SA

MR

TERM

1

2

MS

TERM

1

REAR WASH PUMP

WIRE

863

600BK

SIZE

1.0

1.0

DEST

NH 40

SA

START SOLENOID

WIRE SIZE

842 3.0

DEST

NH 28

MT

TERM

1

2

MU

TERM

1

WIRE

402

600CF

AIR FILTER

SIZE

1.0

1.0

DEST

NH 2

SA

THERMOSTART

WIRE SIZE

003 2.0

DEST

NH 13

MV

TERM

1

2

MW

TERM

1

2

MX

TERM

A

B

WIRE

1801A

600LH

SRS

SIZE

1.0

1.0

DEST

SC

SA

WIRE

1801B

600LJ

SRS

SIZE

1.0

1.0

DEST

SC

SA

PRIMARY FUSE 1 (GREY)

WIRE

200B

200C

200E

200R

SIZE

4.0

4.0

4.0

4.0

DEST

NH 21

NH 22

NH 24

NH 27

MY

TERM

A

B

PRIMARY FUSE 2 (BLUE)

WIRE

200G

SIZE

4.0

DEST

NH 25

200V

200D

200M

4.0

4.0

4.0

NH 16

NH 23

NH 26

R

TYPE

S,T

S,T

—

TYPE

AF,AE

C,D

TYPE

BB

BB

C,D

TYPE

BB

BB

AH

TYPE

AJ

J,K

TYPE

L,M

L,M

—

TYPE

AP,V

AJ

AG

TYPE

AJ

AJ

NG

TERM

A

B

NJ

TERM

1

NK

TERM

A

B

NC

TERM

1

2

3

ND

TERM

A

B

C

NA

TERM

1

2

NB

TERM

1

2

NF

TERM

A

B

HSC SOLENOID

WIRE

867B

SIZE

1.0

600DE 1.0

DEST

NH 45

SA

SHOVEL RESET

WIRE

844

SIZE

1.0

600D 1.0

DEST

ND A

SA

WIRE

408

FUEL SENDER

SIZE

1.0

600CE

514

1.0

1.0

RESET SWITCH

WIRE SIZE

844

600LW

1851

1.0

1.0

1.0

WIRE

101AS

1857

HSC SWITCH

SIZE

1.0

1.0

DEST

NH 39

SA

NH 43

DEST

NB 1

SA

NH 37

DEST

NH 5

NH 8

DUMP SWITCH

WIRE

934A

600EZ

SIZE

1.0

1.0

DEST

NH 42

SA

WIRE

617

EARTH

SIZE

1.0

DEST

NH 29

SEAT CONNECTOR

WIRE

114C

600DH

SIZE

2.0

2.0

DEST

NH 14

SA

AK

TYPE

G,AB

G,AB

—

TYPE

Y,AN

AK

TYPE

G,AB

G,AB

AR,AS

TYPE

BF

BF

BF

AU,AV

TYPE

BB

BB

BB

AK

TYPE

G,AB

G,AB

C,D

TYPE

BB

BB

C,D

TYPE

BB

BB

—

MD 1

—

—

MX A

MX A

MY B

MX B

MY A

MY B

MX B

MS 1

NJ 1

—

—

—

—

—

—

—

ND C

MH 1

NC 1

MR 1

MC C

NG A

NC 3

MG 3

NA 1

ML 1

MK 1

MP 1

MM 1

—

MN 1

SC

MU 1

NK A

—

MY A

DEST

SB

MT 1

MA 1

MC A

NF A

—

—

NF B

514

513

867B

409

412

839

—

—

1851

407

408

863

109

934A

CAB PANEL BLK HD

WIRE

105

402

403

819

101AS

—

—

1857

SIZE

1.0

1.0

1.0

1.0

1.0

—

—

1.0

2.0

4.0

4.0

—

—

—

4.0

4.0

4.0

4.0

4.0

3.0

1.0

—

—

—

—

—

1.0

—

1.0

1.0

2.0

2.0

—

4.0

1.0

1.0

1.0

1.0

1.0

1.0

—

—

1.0

1.0

1.0

1.0

1.0

1.0

200B

200C

200D

200E

200G

—

—

—

814

903

—

406

1801

003

114C

—

200V

200M

200R

842

617

—

—

—

—

—

20

21

22

23

24

25

17

18

19

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

NH

4

5

6

7

8

TERM

1

2

3

12

13

14

15

16

9

10

11

U

BB

BA

U

U

BA

BA

BA

BA

BA

BA

BA

BB

U

U

U

U

U

BF

BF

BF

BF

BF

BF

U

U

BF

BF

BF

BF

BF

BF

E,F

TYPE

BF

BF

BF

BF

BF

P

P

BF

BC

BC

U

BA

BF

P

BF

BF

SIZE

1.0

1.0

1.0

SIZE

1.0

1.0

1.0

H,AY

DEST

NH 1

MF 1

MG 1

H,AY

DEST

NH 12

MV 1

MW 1

MT 2

ML 2

MV 2

MW 2

NB 2

NA 2

ND B

NG B

MA 2

NK B

H,AZ

DEST

MB 1

MD 2

NC 2

MC B

MG 2

MP 2

MR 2

MN 2

721/10935_2

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

2.0

SIZE

4.0

2.0

1.0

1.0

1.0

1.0

1.0

1.0

SB

WIRE

105

105A

105B

SC

WIRE

1801

1801A

1801B

600CF

600JT

600LH

600LJ

600D

600DE

600LW

600EZ

600MC

600DH

SA

WIRE

600A

600B

600CE

600BW

600

600BG

600BK

600CK

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

*

Harness Drawing — Rear Lights / Hydraclamp — Sideshift, page 1 of 1 — CAD 721/10944 Issue 1

Key to Connectors:

LA

LB

LC

LD

SA

SB

Cab Plug

Hydraclamp

RH Rear Lights

LH Rear Lights

Earth

Brake Lights

Purchased from www.WorkshopManuals.co.uk

721/19044

www.WorkshopManuals.co.uk

Harness Drawing — Rear Horn / Alarm — Sideshift, page 1 of 1 — CAD 721/10946 Issue 1

C50

TERM

1

2

WIRE

847A

600CD

SIZE

1.0

1.0

DEST

C103

S10

A,B

TYPE

C,D

C,D

C40

TERM

1

2

REARSOCKET

WIRE SIZE

830E

600BB

1.0

1.0

DEST

S20

S10

N

TYPE

P

P

C60

TERM

1

2

REARFOGLIGHT

WIRE

835

600BJ

SIZE

1.0

1.0

DEST

C101

S10

A,B

TYPE

C,D

C,D

C70

TERM

A

B

WIRE

830G

600AX

SIZE

1.0

1.0

DEST

S20

S10

E

TYPE

G,H

G,H

S10

EARTHSPLICE

WIRE

600BB

600CD

600BJ

600AX

600EL

600GL

600BF

1.0

1.4

2.0

1.0

SIZE

1.0

1.0

1.0

DEST

C402

C502

C602

C70B

C202

C104

S20

WIRE

830E

830G

830T

SIZE

1.0

1.0

1.0

DEST

C401

C102

C20

TERM

1

2

WIRE

871

600EL

HORN

SIZE

1.4

1.4

DEST

C106

S10

J,K

TYPE

L,M

L,M

Connector Key

C10 Cab Connecion

C20

C30

C40

Horn

Horn Button

Rear Socket

C50

C60

C70

S10

S20

Reverse Alarm

Rear Fog Light

No Plate Light

Earth Splice

Side Light Splice

7

8

5

6

3

4

C10

TERM

1

2

CABCONNECTION

WIRE SIZE

835

830T

1.0

1.0

847A

600GL

921

871

—

—

1.0

2.0

1.0

1.4

—

—

DEST

C601

S20

C501

S10

C201

—

—

R,S

TYPE

T

T

X

X

T

T

T

U

C30

TERM

A

B

HORNBUTTON

WIRE

921

600BF

SIZE

1.0

1.0

DEST

C105

S10

E

TYPE

G,H

G,H

Purchased from www.WorkshopManuals.co.uk

721/10946_1

www.WorkshopManuals.co.uk

Harness Drawing — Rear Horn / Alarm — Centre Mount page 1 of 1 — CAD 721/10947 Issue 1

C50

TERM

1

2

WIRE

847A

600CD

SIZE

1.0

1.0

DEST

C103

S10

A,B

TYPE

C,D

C,D

C40

TERM

1

2

REARSOCKET

WIRE

830E

600BB

SIZE

1.0

1.0

DEST

S20

S10

N

TYPE

P

P

C60

TERM

1

2

REARFOGLIGHT

WIRE SIZE

835

600BJ

1.0

1.0

DEST

C101

S10

A,B

TYPE

C,D

C,D

C70

TERM

A

B

WIRE

830G

600AX

SIZE

1.0

1.0

DEST

S20

S10

E

TYPE

G,H

G,H

S10

EARTHSPLICE

WIRE

600BB

600CD

600BJ

SIZE

1.0

1.0

1.0

600AX

600EL

600GL

600BF

1.0

1.4

2.0

1.0

DEST

C402

C502

C602

C70B

C202

C104

S20

WIRE

830E

830G

830T

SIZE

1.0

1.0

1.0

DEST

C401

C102

C20

TERM

1

2

WIRE

871

600EL

HORN

SIZE

1.4

1.4

DEST

C106

S10

J,K

TYPE

L,M

L,M

Connector Key

C10 Cab Connecion

C20

C30

C40

C50

C60

Horn

Horn Button

Rear Socket

Reverse Alarm

Rear Fog Light

C70

S10

S20

No Plate Light

Earth Splice

Side Light Splice

7

8

5

6

3

4

C10

TERM

1

2

CABCONNECTION

WIRE SIZE

835

830T

1.0

1.0

847A

600GL

921

871

—

—

1.0

2.0

1.0

1.4

—

—

DEST

C601

S20

C501

S10

C201

—

—

R,S

TYPE

T

T

X

X

T

T

T

U

C30

TERM

A

B

HORNBUTTON

WIRE

921

600BF

SIZE

1.0

1.0

DEST

C105

S10

E

TYPE

G,H

G,H

Purchased from www.WorkshopManuals.co.uk

721/10946_1

www.WorkshopManuals.co.uk

Harness Drawing — Auxiliary — Excavator page 1 of 1 — CAD 721/10974 Issue 1

C50

TERM

1

2

MICROSWITCH

WIRE SIZE

101AA

899

1.0

1.0

DEST

S10

C106

A,B

TYPE

K,L

K,L

C40

TERM

1

2

WIRE

874C

600CX

SIZE

1.0

1.0

DEST

C103

S20

A,B

TYPE

K,L

K,L

C30

TERM

A

B

WIRE

101Z

875

SIZE

1.0

1.0

DEST

S10

C105

C

TYPE

M,N

M,N

S10

IGN+SPLICE

WIRE

101Y

101Z

101AA

SIZE

1.0

1.0

1.0

S20

EARTHSPLICE

WIRE

600CX

600CJ

600KH

SIZE

1.0

1.0

2.0

H,J

DEST

C102

C501

H,J

DEST

C402

C202

C107

Connector Key

C10 Cab Connecion

C20 Hammer Solenoid

C30

C40

C50

S10

S20

Jaw Change Over Switch

Jaw Change Over Solenoid

Micro Switch

Ignition and Splice

Earth Splice

6

7

8

4

5

C10

TERM

1

2

3

870

875

899

600KH

—

CABCONNECTOR

WIRE SIZE

—

101Y

874C

1.0

1.0

—

1.0

1.0

1.0

2.0

—

DEST

—

S10

C401

C201

C30B

C502

S20

—

TYPE

S

P

P

P

R

S

P

P

Purchased from www.WorkshopManuals.co.uk

C20

TERM

1

2

HAMMERSOLENOID

WIRE

870

600CJ

SIZE

1.0

1.0

DEST

C104

S20

D,E

TYPE

P

P

721/10974_1

i

Section D

www.WorkshopManuals.co.uk

Controls

Section D i

Contents

Steering Column

Removal and Replacement

Dismantling and Assembly

Page No.

30 — 1

30 — 1

31 — 1

Shovel Reset (214e Machines)

Return To Dig

Operation

Adjustment

33 — 1

33 — 1

Precision Control (Servo)

Machines up to serial no. 931159

Basic System Operation

— Component Location

— Component Identification

35 — 1

35 — 2

— Circuit Description

— Electrical Operation

— Hydraulic Operation

35 — 2

35 — 4

35 — 4

Electrical Connections

Fault Finding

36 — 1

37 — 1

Service Procedures

— Testing the Pilot Pressure

— Renewing the Pilot Supply Valve Oil Filter

— Pilot Hose Removal and Replacement

— Seat Arms Control Lever — Adjustment

Pilot Control Valves

— Removal and Replacement

— Dismantling and Assembly

— Electrical Switches Removal and Replacement

38 — 1

38 — 1

38 — 3

38 — 4

40 — 1

40 — 3

41 — 1

Precision Control (Servo)

Machines from January 2003

Basic System Operation

— Component Location

— Component Identification

— Circuit Description

— Hydraulic Operation

45 — 1

45 — 2

45 — 2

45 — 3

— Electrical Operation

Joystick Controller 45 — 6

Pump Dump Controller (Power Management ECU) 45 — 6

— Joystick Controllers — Description

— Servo Pressure Supply Valve — Description

45 — 7

45 — 8

47 — 1 Fault Finding

Service Procedures

— Testing the Servo Pressure 48 — 1

Joystick Controllers

— Removal and Replacement

— Dismantling and Assembly

50 — 1

50 — 2

9803/3280 Issue 4*

Purchased from www.WorkshopManuals.co.uk

ii

Section D

www.WorkshopManuals.co.uk

Controls

Section D ii

Contents Page No.

Precision Control (Servo)

Machines from January 2003

(continued)

Servo Pressure Supply Valve

— Removal and Replacement

— Dismantling and Assembly

51 — 1

51 — 2

Control Rods and Linkages

Dismantling and Assembly

— Loader Valve Controls

— Excavator Valve Controls

Control Cables

Removal and Replacement

— Cab Heater Controls

— Stabiliser Controls

— Boom Lock Cable

Boom Stop Setting

— Engine Throttle Cable

— Auxiliary Footpedal Cable

60 — 1

61 — 1

70 — 1

71 — 1

72 — 1

72 — 1

73 — 1

74 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

30 — 1

www.WorkshopManuals.co.uk

Controls

Steering Column

Section D

30 — 1

A

C

C

B

B

B

B

L

N

R

M

P

F

F

H

T

S

E

H

H

D

G

H

9803/3280

G

J

Purchased from www.WorkshopManuals.co.uk

A396921

Issue 2*

Section D

30 — 2

www.WorkshopManuals.co.uk

Controls

Steering Column

Section D

30 — 2

Removal and Replacement

The steering column can be tilted to improve operator reach and comfort levels. This type of assembly is refered to as a

‘tilt column’.

The illustration on the adjacent page is intended as a guide to removal and replacement.

Removal

*

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground. Switch OFF the engine, remove the starter key and disconnect the battery.

2

Remove the steering wheel as shown at

A

.

3

Remove socket screws

B

and take off the steering column pedestal cover.

4

Remove the control column switches

C

.

*

5

Remove the socket screw

D

securing the gas damper strut

E

.

6

Remove socket screws

F

and lift up the rubber protective cover behind the brake pedals to gain access to the flexible coupling.

*

7

Remove the coupling bolt

G

and shoulder bolts

H

.

Then carefully withdraw the steering column assembly

(with the gas damper strut attached) from the flexible coupling

J

.

Replacement

Replacement is the reverse of the removal sequence.

*

Apply JCB Threadlocker and Sealer to threads of nuts

T

.

Note:

The coupling bolt

G

must engage with the cut-out in the shaft.

*

After re-fitting check that the steering tilt functions correctly, and that the direction indicators and lights operate correctly.

Check that the wires from the brake pedal switch do not rub on the steering column.

*

Torque Settings

Item

D

H

Nm

14

40

kgf m lbf ft

1.4

4.1

10.3

29.5

Dismantling and Assembly

The illustration on the adjacent page is intended as a guide to dismantling and assembly.

Dismantling

1

Using a screwdriver in the slot, carefully prise out the dust seal

L

from the outer column tube.

2

Remove external circlip

M

, washer

N

, tolerance ring

P

and withdraw the steering shaft from the outer column tube and pivot bracket.

Note:

The top and bottom bearings

R

and

S

housed in the outer column tube are non serviceable parts. They may be removed for cleaning and inspection, but if the bearing(s) have failed a new outer column tube and pivot bracket assembly must be used.

Note:

The gas damper strut

E

is a non serviceable part. If the damper is faulty it must be replaced with a new one.

Assembly

Assembly is the reverse of the dismantling sequence.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section D

31 — 1

www.WorkshopManuals.co.uk

Controls

Shovel Reset

Section D

31 — 1

H

B

C

F

E

G

H

A

2065mm

J

M

K

9803/3280

L

Purchased from www.WorkshopManuals.co.uk

A320510

Issue 1

Section D

31 — 2

www.WorkshopManuals.co.uk

Controls

Shovel Reset

Section D

31 — 2

214e Machines Only

The shovel reset system is designed to automatically tilt the shovel forward when the loader arms are raised, this prevents a heaped shovel from depositing its contents over the back of the shovel onto the bonnet or cab when the loader arms are raised.

When the loader arms are raised the feed back link

A

causes the cam plate

B

to rotate anti-clockwise. The rotation of the cam plate pulls the cable

C

which selects the loader valve block shovel spool

D

to tip the shovel forwards.

When either a cable or feedback link is changed or if the shovel reset system is not operating correctly carry out functional adjustment check.

D

C

A

B

Fitting

1

Adjust the feedback link

A

to 2065mm (81.3in). After adjusting tighten the lock nuts.

2

Fit cam plate

B

with the single threaded hole at the top.

3

Fit feed back link

A

to cam plate and shovel lever

E

.

4

Connect cable

C

to the bottom centre position

F

on the cam plate

B

, secure in position.

Note

: The factory fit position for the cable end ball joint to cam plate is the centre position. Because of component variation it is permissible to fit the cable end ball joint in either the forward or rear position. The forward position will advance the levelling and the rear position will delay the levelling.

5

Connect cable

C

to the loader arm control lever

G

.

6

Secure cable ends with spring clips

H

.

7

Carry out the adjustment procedure.

Adjustment

1

Roll the shovel fully back and lower to the ground.

2

The feedback link position in relation to the loader arm pivot pin measurement

J

should be 40mm (1.5in).

Adjust feedback link as required.

3

When the loader arms are raised there should be no slack in the cable at

K

when the shovel arm pivot pin

L

is 1.0 to 1.5 meters (3.5 to 5.0 feet).

4

Roll the shovel fully forward and fully retract the lift arms, this will raise the front wheels off the ground.

5

In this position there should be slack in the cable at

M

, if not adjust the cable as required.

Note

: Whenever any adjustment is made repeat steps 4/5 to make sure there is slack in the cable with the shovel rolled fully forward.

A320500

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

33 — 1

www.WorkshopManuals.co.uk

Controls

Return To Dig

Section D

33 — 1

2

X

1

9803/3280

Purchased from www.WorkshopManuals.co.uk

A374040

Issue 1

Section D

33 — 2

www.WorkshopManuals.co.uk

Controls

Return To Dig

Section D

33 — 2

Operation

This enables you to roll the shovel from the rolled forward position into the digging position quickly and easily.

When you select ‘Return To Dig’ a proximity switch on one of the loader arms cuts off the hydraulic pressure to the shovel rams immediately the shovel reaches the correct angle for digging.

To select ‘Return To Dig’:

1

Press the ‘Return To Dig Enable’ switch

A

to the ON position, the switch will illuminate.

2

Pull the loader lever to the left as far as it will go. You will feel a slight pressure on the lever as it passes through the

Roll Back

position.

Release the lever, it will stay in the detent position until the shovel reaches the return to dig position when the lever will automatically return to the central hold position.

3

When return to dig is no longer required press the enable switch to the OFF position.

Adjustment

1

Lower the loader arms and position the shovel in the required ‘Return To Dig’ position.

2

Switch OFF the engine but leave the ignition ON.

3

Press the ‘Return To Dig Enable’ switch to ON.

4

Adjust the rod with nuts

1

so that the LED on the proximity switches illuminates/extinguishes at this position.

5

Adjust the proximity switch with nuts

2

to give a clearance

X

of 2 mm (0.08 in).

A

9803/3280

A401050

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

35 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

35 — 1

Basic System Operation

Component Location

B

C

J

S

A

L

S

U

M

P

V

R

H

K

P

D

Q

E

U

N

U

U

T

F

G

U

9803/3280

A402030

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

35 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

35 — 2

Basic System Operation

Component Identification

P

Q

R

S

T

J

K

L

M

N

U

V

D

E

F

G

H

A

B

C

Right hand joystick

Left hand joystick

Operator seat

Pilot supply valve

Supply valve solenoid

Oil filter access plug

Accumulator

Right hand pilot control valve

Left hand pilot control valve

Seat mounted micro switch

Joystick mounted ‘mode switch’

Loader valve block

Excavator valve block

Hose sleeves

Pressure relief valve

Hose clamps (seat base mounted)

Mechanical linkages

Machine hydraulic tank

Bolt on spool section — extending dipper (if fitted)

Plastic cover panel

* The following section describes the JCB Precision Control system fitted to machines up to serial number 931159. There is another JCB Precision Control system fitted to later machines, which is described in a separate section. Refer to

Precision Control (Servo) — Machines from January 2003

.

Circuit Description

The JCB Precision Control system facilitates operation of the backhoe (excavator) via joysticks

A

and

B

mounted in the arms of the operator’s seat. Unlike manual machines the excavator valve spools are moved by hydraulic pressure and not directly by a mechanical levers.

A pilot supply valve

D

maintains a constant supply of oil at servo pressure to the right and left hand pilot control valves

H

and

J

. The valves are mounted at the rear of the seat arm rests.

The joysticks each operate a hydraulic pilot control valve (

H

or

J

as applicable) via a mechanical linkage. These valves in turn operate the excavator valve spools via hydraulic pilot pressure. The interconnecting hoses are routed to and from the pilot control valves through the central seat support pillar and then through the cab floor.

The mechanical linkages

S

incorporate universal type couplings at both ends.

The joysticks control boom, dipper, bucket and slew functions. Unlike manual control machines, the foot pedal controlled auxilary valve spool (typically used to operate the extending dipper ram) is located on the loader valve block.

For details of this valve spool see Section E.

The seat arms incorporating the joysticks are adjustable for both height and length. A gas strut mounted in the left hand arm supports the weight of the assembly when adjusting the height.

Note: Precision control machines — extending dipper.

When fitted, the extending dipper ram is controlled by bolt on spool section

U

located on the loader valve. The spool is actuated by the normal foot pedal via a cable.

E

Q

D

9803/3280

F

A402080

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section D

35 — 3

4

P

T

3

2

1

J

Controls

Precision Control (Servo)

www.WorkshopManuals.co.uk

M

R

L

K

SAE +

TR TL T

E

F

D

Q

B

4J

3J

1J

2J

PL

PR

G

TP

P

S1b

S2b

S1a

S2a

P

3

2

T

4

1

H

3H

2H

A

1H

4H

S3b

S4b

N

S3a

S4a

T

SAE +

Z

ISO +

S3a 4J

2J

S3b

9803/3280

3 2 1 P T 4

S2a

3H 1H

S2b

Key to Oil Flow & Pressure

Full Pressure

Servo

Exhaust

Purchased from www.WorkshopManuals.co.uk

A402070

D

G

S

E

H

F

TP

PL

P

TR TL PR

J

T

P

4

3

2

1

2

1

Q

TL

T

T

P

3

4

Section D

35 — 3

Issue 1

Section D

35 — 4

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

35 — 4

Basic System Operation

N

P

Q

R

S

H

J

K

L

M

S1a

S1b

S2a

S2b

S3a

S3b

S4a

S4b

T

A

B

D

E

F

G

Component Key:

Right hand joystick

Left hand joystick

Pilot supply valve

Supply valve solenoid

Oil filter

Accumulator

Right hand pilot control valve

Left hand pilot control valve

Seat mounted micro switch

Joystick mounted ‘mode switch’

Loader valve block

Excavator valve block

Machine hydraulic tank

Pressure relief valve

Fuse

Solenoid manual override control knob

Excavator Pilot port — Slew ram spool

Excavator Pilot port — Slew ram spool

Excavator Pilot port — Boom ram spool

Excavator Pilot port — Boom ram spool

Excavator Pilot port — Dipper ram spool

Excavator Pilot port — Dipper ram spool

Excavator Pilot port — Bucket ram spool

Excavator Pilot port — Bucket ram spool

Tank

Note that the diagram opposite shows the servo hoses connected to give the SAE + (JCB +) control pattern. For

ISO + control pattern some servo hoses are connected differently at the excavator valve, as shown at

Z

.

Electrical Operation

A solenoid actuated valve is incorporated in the pilot supply valve block

D

. The solenoid is controlled either by micro switch

K

or ‘mode switch’

L

.

When the operator seat is revolved to face the rear of the machine switch

K

is closed. This energises solenoid

E

and oil at pilot pressure is diverted to the 2 pilot control valves

H

and

J

, thus enabling the system. Solenoid

E

also incorporates a manual override facility (

S

). This enables the backhoe to be operated in an emergency situation, in the event of solenoid or electrical failure for example.

In some circumstances the operator may require actuation of the backhoe with the seat in the forward position (when un-sticking from boggy ground for example). This is achieved by means of joystick mounted mode switch

L

. The switch energises solenoid

E

and the system is enabled.

The left hand joystick houses a horn switch. On some machines the joysticks also incorporate switches for control of a hydraulic quickhitch and changeover from auxilary

(typically jaw bucket) to extending dipper operation.

Hydraulic Operation

Oil at system pressure flows to the pilot supply valve

D

via a hose connected at the loader valve

M

. An integral pressure relief valve

Q

maintains the oil at ‘pilot’ pressure.

When the operator actuates the system by revolving the seat to face the rear, or by operating the mode switch, solenoid

E

is energised and moves the pilot supply valve spool. Oil flows to the pilot control valves

H

and

J

.

Each pilot control valve contains four spool valve ‘capsules’, numbered 1 to 4 on each valve. The valves are operated by moving the associated joystick. With the joystick in the neutral position all the valves vent oil from the excavator valve pilot ports S1-S4 to tank.

Example Operation:

When the operator moves the right hand joystick forward the mechanical linkage connected to pilot valve

H

pushes spool 1 down. Oil at pilot pressure is diverted to port S3b.

in the excavator valve

N

. This causes the dipper spool to move and operate the dipper ram. As the dipper spool moves, oil is vented from port S3a via spool 3 and port T in control valve

H

.

The valve ‘capsules’ feature proportional control. This enables backhoe precision control. Each valve capsule modulates oil pressure supplied to the associated excavator valve pilot line in proportion to the joystick position. The further the joystick is moved the greater the pilot pressure and the further the associated excavator valve spool moves.

Accumulator

G

maintains hydraulic pressure for several operations of the excavator spools with the engine stopped.

This allows venting of pressure from the backhoe hydraulic rams, or lowering of a load in the event of engine failure.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

36 — 1

Electrical Connections

Controls

Precision Control (Servo)

www.WorkshopManuals.co.uk

HB HD

HH

Section D

36 — 1

7

A1

101AG

SH

CP

3

875B

TA

DR2

8

9

CM

6

5

SC

4

3

2

1

101Y

875

600KH

2

5

7

4

3

2

1

CTG

5

6

7

8

5

6

7

8

921

929

931

5

7

8

4

3

2

1

CTB

5

6

7

8

HF

10

4

3

2

1

5

6

7

8

5

6

7

8

HA

4

3

2

1

2

101BG

5

6

7

8

HB

4

3

2

1

2

5

7

101Y

875

600KH

5

6

7

8

HD

4

3

2

1

5

7

8

921

929

931

5

6

7

8

HC

4

3

2

1

1

SD

600GT

921

930

931

1

2

3

4

1

2

HH

4

3

4

3

1

2

1

2

3

4

3a

3b

3

4

5

SB

1

1 2

2

101BJ

1

1

HG

2

2

1805C

SA

1

1 2

2

1805F

1

1

HE

2

2

600HX

101N

1805C

929

930

101Z

875

3

4

5

6

1

2

1

2

3

HF

6

5

4

6

5

4

1

2

3

4

5

6

1

2

3

2a

2b

2c

2

HG

HB

HD

9803/3280

HA HC

HE

A402400

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

36 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

36 — 2

Electrical Connections

On the electrical diagram opposite the electrical connectors

(example, CTG to HB) are shown looking on the mating face of each connector when they are disconnected.

The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding.

Before fault finding make sure that you understand how the the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and soleniod coils. See

Service

Procedures, Electrical Testing Methods

for more details.

Component Key:

1

Servo harness

HA

Auxiliary hydraulics harness loop connector

HB

Auxiliary hydraulics connector

HC

Rear cab harness loop connector

HD

Rear cab harness connector

HE

Pilot control valve solenoid connector

HF

Right hand joystick connector

HG

Seat microswitch connector

HH

Left hand joystick connector

2

Right hand joystick

2a

Microswitch — Mode

2b

Microswitch — Excavator quickhitch latch control (if fitted)

2c

Microswitch — Hydraulic changeover solenoid valve

(if fitted)

3

Left hand joystick

3a

Microswitch — Rear Horn

3b

Microswitch — Excavator quick hitch latch control (if fitted)

4

Seat mounted microswitch

5

Pilot control valve solenoid

6

Auxiliary hydraulics wiring harness, see

Basic System

Operation, Circuit Schematics

7

Hydraulic change over circuit, see

Basic System

Operation, Circuit Schematics, Auxiliary and

Hydraclamp Hydraulics

8

Rear horn circuit, see

Basic System Operation, Circuit

Schematics

9

Dedicated quick hitch circuit, see

Basic System

Operation, Dedicated Quick Hitch

10

Rear cab harness

A1

Fuse — Hydraulic Auxiliary

CP

Relay base — Auxiliary (jaw bucket)

CM

Relay base — Rear horn

Splices:

SA

SB

SC

SD

SH

TA

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

37 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

37 — 1

Fault Finding

Introduction

The fault finding procedures are given in the form of flow charts. There are a number of charts, each one dedicated to a particular fault. The charts are designed to identify possible causes by performing checks and where applicable, specific tests. Having identified a cause the suggested remedy is given. The charts are designed to identify causes through a process of elimination, starting with the simplest, most easily rectified faults.

Before proceeding:

1

Make sure that the hydraulic fluid is at the correct working temperature (50 o

C, 122 o

F).

2

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

3

Replace any seals such as ‘O’ rings before assembling hydraulic components.

Fault Finding Charts:

Chart A

— No Servo Controls (system fails to operate)

Chart B

— All Backhoe Services Slow to Operate

Chart C

— One Backhoe Service fails or is Slow to Operate

Chart D

— System Fails to Operate when the ‘Mode Switch’ is Activated (operator seat facing forward)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

37 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Fault Finding

Chart A — No Servo Controls (system fails to operate)

Section D

37 — 2

START

YES

YES

See Electrical Switches, Seat

Mounted Microswitch — Adjustment.

Check seat mounted micro switch function and condition of associated wiring for damage. Repair or renew as applicable.

Renew coil.

Does system function if the ‘mode’ switch is operated?

NO

Is the supply valve solenoid coil faulty?

NO

Is the relevant electrical fuse intact?

YES

Is the wiring to the supply valve solenoid coil intact?

YES

Renew pilot supply valve solenoid valve stem.

NO

NO

Inspect and test all relevant wiring for damage and short circuits.

Repair as applicable. Renew the fuse.

Repair as applicable.

See Electrical Connections.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402360

Issue 1

Section D

37 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

37 — 3

Fault Finding

Chart B — All Backhoe Services Slow to Operate

START

Is the pilot supply valve oil filter blocked?

NO

Is the pilot oil pressure low?

NO

Is the pilot supply valve operating correctly? Remove the valve stem

YES and check for signs of contamination or sticking.

YES

YES

NO

Renew filter. Remove any contamination. Check condition of hydraulic oil, drain and replace if necessary.

See Section 3, Routine Maintenance.

Adjust as required.

See Service Procedures, Testing the

Pilot Pressure.

Repair or renew as applicable.

See Electrical Connections.

YES

Are the joystick linkages worn? Check the condition of the universal joints and actuator plates on the pilot control valves.

See Pilot Control Valves, Dismantling,

Inspection and Assembly.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402370

Issue 1

Section D

37 — 4

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

37 — 4

Fault Finding

Chart C — One Backhoe Service fails or is Slow to Operate

START

Is the associated joystick mechanical linkage worn or wrongly adjusted?

NO

Inspect the associated pilot spool valve capsule for signs of wear, damage or contamination. Is the valve in good working order?

NO

Is the associated service spool in the excavator valve sticking?

NO

See Section E, Hydraulics Fault

Finding, ‘ One hydraulic service fails or is slow to operate’.

YES

YES

YES

Renew or adjust components as applicable.

See Service Procedures, Control

Linkage Adjustment.

Clean and renew components as applicable.

See Pilot Control Valves, Dismantling

Inspection and Assembly.

Rectify as applicable.

See Section E, Hydraulics Fault

Finding, ‘ A spool is sticking’.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402380

Issue 1

Section D

37 — 5

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

37 — 5

Fault Finding

Chart D — System Fails to Operate when the ‘Mode Switch’ is Activated (operator seat facing forward)

START

Does the system operate with the operator seat set in the rear facing position?

YES

Is the relevant wiring damaged?

NO

Is the mode switch functioning correctly?

YES

NO

YES

See Fault Finding Chart A — No Servo

Controls (system fails to operate)

Check for damage and carry out continuity checks. Repair as applicable.

NO

Test and renew switch if applicable.

See Electrical Connections.

See Electrical Switches, Joystick

Mounted Microswitches — Removal and Replacement.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402390

Issue 1

Section D

38 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

38 — 1

Service Procedures

Testing the Pilot Pressure

1

Position the backhoe to enable access to the pilot supply valve.

Before proceeding further the pilot circuit accumulator pressure must be vented.

2

Stop the engine. With the operator seat set in the rear facing position (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the servo pressure from the accumulator. Switch the starter switch to the OFF position.

3

Connect a 0 — 50 bar pressure gauge to the test point

A

.

4

With the engine running at 1500 revs/min, operate a backhoe service fully. At the same time check the reading on the gauge. It should be 35 bar (36 kgf/cm

2

507 lbf/in

2

).

If necessary adjust the pressure as follows:

1

Stop the engine. Loosen lock nut

B

and adjust screw

C

.

Turn screw

C

clockwise to increase pressure and anticlockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required.

C

B

Renewing the Pilot Supply Valve Oil Filter

1

Position the backhoe to enable access to the pilot supply valve.

2

Stop the engine. Clean off all dirt on and around the filter cap

D

. Undo the cap. Remove and discard the filter element. The servo system is easily damaged by contaminated hydraulic oil. When installing a new filter element make sure that no dirt is allowed to enter the pilot supply valve.

D

A

A402080

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

38 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

38 — 2

D

F

D

A

D

C

E

A402430

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

38 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

38 — 3

Service Procedures

Pilot Hose Removal and Replacement

Before attempting to remove a servo hose the pilot circuit accumulator pressure must be vented.

1

Stop the engine. With the operator seat set in the rear facing position (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the servo pressure from the accumulator. Switch the starter switch to the OFF position.

2

Note the phasing and routing of the hose to be renewed. Working under the machine, disconnect the applicable hose. Note that the hoses have tags to identify their connections. Plug the open ports. Remove the hose from any ties under the machine.

3

Working in the cab remove the plastic shrouds

A

from the seat as required. Disconnect the hose at the pilot control valve

B

. Note that the hoses have tags to identify their connections Attach some strong string or cord to the end of the disconnected hose.

.

4

Undo the hose clamp

C

at the base of the seat frame.

5

Draw the hose up into the cab through pedestal

E

and sleeves

D

. Undo the string from the end of the hose.

6

Make sure that the open ends of the new hose are plugged. Tie the correct end of the hose to the string.

Draw the hose down through the sleeves

D

and pedestal

E

.

7

Remove the string and connect the hose as applicable, making sure to phase it correctly. Refit the hose clamp

C

.

8

Tag the new hose at both ends to identify its connections.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

38 — 4

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

38 — 4

Service Procedures

Seat Arms Control Lever — Adjustment

In some instances it may be necessary to adjust the operation of the arms raise/lower control lever

1

.

When the button

2

is depressed upwards fully, the arms are released for raise/lower. If the arms are not released, or release but re-lock when the button is fully depressed, adjust the control lever as follows:

If the arms do not release

1

Slacken lock nut

3

and screw the stop bolt

4

out (anticlockwise). Test the operation of the control lever and then tignten the lock nut

3

.

If the arms release but re-lock

1

Slacken lock nut

3

and screw the stop bolt

4

in

(clockwise). Test the operation of the control lever and then tighten the lock nut

3

.

2

9803/3280

1

3

4

Purchased from www.WorkshopManuals.co.uk

A402560

Issue 1

Section D

40 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

40 — 1

4

3

1

1

2

9

8

10

5

6

8

A402540

7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

40 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

40 — 2

Pilot Control Valves

Removal and Replacement

Note that the procedure shows the right hand control valve.

The removal and replacement procedure for the left hand valve is identical.

Before attempting to remove a pilot control valve the pilot circuit accumulator pressure must be vented.

1

Stop the engine. With the operator seat set in the rear facing position (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the servo pressure from the accumulator. Switch the starter switch to the OFF position.

Removal

1

Reach inside the arm assembly and undo the two arm rest fixing bolts

1

. Carefully lift the rear of the arm rest

2

and pull it to the rear to release.

2

Undo the retaining screws and remove the plastic covers

3

and

4

. Undo and remove bolt

5

together with lock washer

10

. Lift the link rod

6

to one side.

3

Note the phasing of the hoses connected at the valve

7

.

If the hoses are not already tagged, tie on your own tags. Make sure you have recorded the connections correctly, enabling correct re-connection when replacing the valve. Disconnect the hoses at the valve.

Cap all open hoses and ports.

4

Undo the three fixing bolts

8

and lift out the valve.

Replacement

Replacement is the reverse of removal. Make sure that the joystick gaiter

9

is correctly located.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

40 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

40 — 3

1

3

15

6

7

14

6

7

5

2

8

Y

X

9

8

10

11

5

A

Z 2

B

Z

2

4

16

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402440

Issue 1

Section D

40 — 4

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

40 — 4

Pilot Control Valves

Dismantling, Inspection and Assembly

Note that the procedure shows the right hand control valve.

The procedure for the left hand valve differs only in the location of one way restrictors

4

and orientation of joint mechanism assemblies

2

.

Dismantling

1

Undo the three cap screws

1

. Lift off the joint mechanism assembly

2

.

2

Pull out the four valve capsule assemblies

3

.

3

Remove the six adaptors

16

from the ports. Note that the adaptors incorporate seals. Note that one way restrictors

4

are fitted to some ports as follows:

Right hand valve — ports 1 and 3.

Left hand valve — ports 2 and 4.

Inspection

1

Inspect the underside of the wobble plate

5

for signs of excessive wear. If wear is evident the complete assembly

2

must be renewed.

2

Inspect the universal joint for signs of excessive play. If wear is evident the complete assembly

2

must be renewed.

3

Inspect the mating faces of plungers

6

and bushes

7

for signs of excessive wear. If wear is evident the valve capsule must be renewed as a complete assembly.

4

If the valve has been contaminated with debris be sure to remove it from all internal drillings. Carefully inspect the mating faces of spools

8

and body

9

. If scoring is evident the complete valve must be renewed.

5

Make sure that one way restrictors

4

are free from debris.

Assembly

Assembly is the reverse dismantling but note the following:

1

The valve assembly is susceptible to malfunction and damage if it is contaminated with debris or dirt. Make sure that all components are clean and free from debris.

2

Renew all ‘O’ rings

14

and seals

15

.

3

Be sure to fit the one way restrictors

4

the correct way up and in the correct ports. See Dismantling, Step 3.

4

Apply JCB HP Grease to the mating faces of wobble plate

5

and plungers

6

.

5

Be sure to orientate the joint mechanism assembly

2

correctly. On left hand valves note that the slot

Z

aligns with port

2

as shown at

A

. On right hand valves the slot

Z

aligns with port

1

as shown at

B

.

6

If the joint mechanism assembly

2

is to be renewed it must be adjusted correctly. With the assembly fixed in position, check the dimension

X

. The wobble plate

5

must be positioned so that it just makes contact with the top of the valve plungers. If there is a gap at

X

, or if the plate is depressing the plungers adjust as follows:

Hold the collar

11

using a suitable rod located in hole

Y

.

Slacken the lock nut

10

and then screw the collar

13

up or down as required. Tighten the lock nut

10

.

Torque Settings:

Item

1

10

16

Nm

9

9

30

Kgf m

1

1

3

lbf ft

7

7

22

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

41 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

41 — 1

C

H

G

B

B

A

P

K

M

E

F

K

L

J

A402410

D

N

J

E

F

9803/3280

A402590

X

W

Purchased from www.WorkshopManuals.co.uk

Z

V

U

Issue 1

Section D

41 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

41 — 2

Electrical Switches

Joystick Mounted Microswitches, Removal and

Replacement

Note that the procedure shows the right hand joystick. the procedure is very similar for the left hand joystick. Note that where the joysticks incorporate more than one switch, all switches must be renewed as a complete harness and switch assembly.

Removal

1

With the operator seat set in the rear facing position (for backhoe operation), pull off the gaiter

A

.

2

Reach inside the arm assembly and undo the two arm rest fixing bolts

B

. Carefully lift the rear of the arm rest

C

and pull it to the rear to release.

3

Uncouple the joystick harness connector

D

from the servo harness. Note the orientation of the joystick.

Slacken the lock nut

E

followed by lock nut

F

. Unscrew the joystick and remove it from the machine. Remove lock nuts

E

and

F

.

4

Drill a small hole in the centre of plastic cap

G

. Screw in a self tapping screw. Using pliers, grip the screw and draw out the cap

G

. Undo screw

H

. Lever off the aluminium base plate

J

.

5

Carefully part the two halves of the joystick making sure that components are not lost. Lift the switches

K

off their location pins. Note that replacement switches are supplied together with a new base plate

J

, wiring harness and connector already assembled.

Replacement

Replacement is the reverse of removal but note the following:

1

When assembling the joystick ensure that the wiring harness is located correctly. Cable tie

L

must be located to prevent strain on the wire connections at the switches. Make sure that bush

M

is fitted correctly (if applicable). If spigot

N

has been removed make sure it is fitted with its alignment pin

P

correctly located. Fit a new plastic cap

G

.

2

When screwing the joystick assembly to the control linkage be sure to orientate it correctly before tightening the lock nut

F

.

Seat Mounted Microswitch, Removal, Replacement and

Adjustment.

Important Note:

Some machines may be fitted with two seat mounted microswitches, one on each side of the seat.

On Precision Control machines only switch

Z

is used. Note that switch

Z

is located on the left side of the seat when set in the rear facing position. When renewing the switch make sure you re-connect the wiring harness to the correct switch.

Under no circumstances attempt to connect to the switch on the right hand side of the seat.

Removal

1

With the operator seat set in the forward facing position

(for loader operation), uncouple the electrical connector

X

. Undo the two retaining screws

W

and remove the switch.

Replacement

Replacement is the reverse of removal.

Adjustment

The switch must be adjusted to operate only when the operator seat is locked in the rear facing position. This is essential for safe operation of the machine, preventing backhoe operation until the operator is correctly seated.

1

With the operator seat set in the rear facing position (for backhoe operation), locate the adjustable bolt

V

on the seat pedestal. Loosen the lock nut

U

and screw the bolt in or out until the switch is heard to operate. Tighten lock nut

U

.

2

Start the machine and test the system.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

45 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

45 — 1

Basic System Operation

Component Location

TBA

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

45 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

45 — 2

Basic System Operation

F

G

H

J

K

A

B

C

D

E

L

Component Identification

Right hand joystick controller

Left hand joystick controller

Operator seat

Servo pressure supply valve

Isolation valve solenoid

Accumulator

Servo pressure regulating valve

Servo pressure relief valve

Loader valve block

Excavator valve block

Hydraulic tank

The following section describes the JCB Precision Control system fitted to machines from January 2003. There is another JCB Precision Control system fitted to earlier machines, which is described in a separate section. Refer to

Precision Control (Servo) — Machines up to serial number

931159

.

Circuit Description

The JCB Precision Control system facilitates operation of the backhoe (excavator) via joystick controllers

A

and

B

mounted in the arms of the operator’s seat. Unlike manual machines the excavator valve spools are moved by hydraulic pressure and not directly by mechanical levers.

A servo pressure supply valve

D

maintains a constant supply of oil at servo pressure to the right and left hand joystick controllers.

The joysticks each directly operate pressure reducing valves.

These valves in turn operate the excavator valve spools via hydraulic servo pressure. The interconnecting hoses are routed to and from the joystick controllers through the central seat support pillar and then through the cab floor.

The joysticks control the boom, dipper, bucket and slew functions.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

45 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

45 — 3

Basic System Operation

Hydraulic Operation

Oil at system pressure flows to the servo pressure supply valve

C

via a hose connected at the excavator valve

J

. An integral pressure regulating valve

F

maintains the oil at

‘servo’ pressure.

When the operator actuates the system by locking the seat in the forward or reverse facing position and raising forward the arm rests, the isolation valve solenoids

D

are energised and oil is directed to the joystick controllers

A

and

B

.

Each joystick controller contains four spool valve ‘capsules’, numbered 1 to 4 on each valve. The valves are operated by moving the associated joystick. With the joystick in the neutral position the valves vent the oil from the excavator valve servo pilot ports to tank

K

.

Example Operation:

When the operator moves the right hand joystick

B

forward this pushes spool 3 down. Oil at servo pressure is directed to port

S5b

at the excavator valve

J

. This causes the boom spool to move and operate the boom ram. As the boom spool moves, oil is vented from port

S5a

via spool 1 and port

T to tank.

The valve ‘capsules’ feature proportional control. This enables backhoe precision control. Each valve capsule regulates the oil pressure supplied to the associated excavator valve pilot line in proportion to the joystick position. The further the joystick is moved the greater the servo pressure and the further the associated excavator valve spool moves.

Accumulator

E

maintains servo pressure for several operations of the excavator spools with the engine stopped.

This allows venting of pressure from the backhoe hydraulic rams, or lowering of a load in the event of engine failure.

Note:

The diagram opposite shows the servo pilot hoses connected to give the ISO + control pattern. For SAE + control pattern the servo pilot hoses are connected differently at the excavator valve as shown at

Z

.

H

J

K

L

M

S1a

S1b

S2a

S2b

S3a

A

B

C

D

E

F

G

S3b

S4a

S4b

S5a

S5b

S6a

S6b

S7a

S7b

Component Key:

Left hand joystick controller

Right hand joystick controller

Servo pressure supply valve

Isolation valve solenoids

Accumulator

Servo pressure regulating valve

Servo pressure relief valve

Loader valve block

Excavator valve block

Hydraulic tank

Stabiliser controls

Auxiliary footpedal

Servo pilot port — Slew ram spool

Servo pilot port — Slew ram spool

Servo pilot port — Dipper ram spool

Servo pilot port — Dipper ram spool

Servo pilot port — R.H. stabiliser ram spool

Servo pilot port — R.H. stabiliser ram spool

Servo pilot port — L.H. stabiliser ram spool

Servo pilot port — L.H. stabiliser ram spool

Servo pilot port — Boom ram spool

Servo pilot port — Boom ram spool

Servo pilot port — Bucket ram spool

Servo pilot port — Bucket ram spool

Servo pilot port — Auxiliary spool (Extending Dipper)

Servo pilot port — Auxiliary spool (Extending Dipper)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

45 — 4

9803/3280

www.WorkshopManuals.co.uk

A A A

LS

B B B

T

Controls

Precision Control (Servo)

H

P

P1

P2

T

1

P

4

2

3

A

L.H.

2

1 3

4

ISO+

C

D

D

E

G

F

S1a

S2a

S3a

S4a

S5a

S6a

S7a

K

1

2

P

T

4

3

2

1

4

B

R.H.

3

ISO+

Z

L.H.

S2a 1

SAE+

3

S2b

P

T

1 2 3 4

R.H.

S5a

1

SAE+

3

S5b

Key to Oil Flow & Pressure

Full Pressure

Servo

Exhaust

Purchased from www.WorkshopManuals.co.uk

1 2

L

2 1

J

S1b

S2b

S3b

S4b

S5b

S6b

S7b

2 1

A404990

M

1H

1H

Section D

45 — 4

Issue 1

Section D

45 — 5

9803/3280

A

60A

Controls

Precision Control (Servo)

B

007

www.WorkshopManuals.co.uk

3A 3A 3A

139

138

137

UNLOADER (HSC) SWITCH

SIDE CONSOLE LED

C

D

929

931

875

3

1

E

5

8

F

10

6

921A

1875

G

1876

1

1874

1877

1

H

2

2

3 3

N

2

1

114C 114E

5

2

628 4

3

1

114G

P

2

629A

3

Q

1

2

629D

3

628C

R

2 628D

1

SA

J

1857

8

12

1

4

10

PUMP DUMP

CONTROLLER

6 2

7

11

9

5

412C

519

520

1

2

8870

1

2

3

M

K

ALTERNATOR FREQUENCY

L

1 921A 921B

S

628A

6

7

8

929

921C

T

628B

U

V

931

875

W

114K

SOME MACHINE VARIANTS ONLY

CAB SEAT MAINFRAME

Purchased from www.WorkshopManuals.co.uk

Section D

45 — 5

A405100

Issue 1

Section D

45 — 6

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

45 — 6

Basic System Operation

Electrical Operation — Joystick Controller

There are two solenoid actuated isolation valves incorporated in the servo pressure supply valve block, which when energised direct servo pressure to enable the R.H. and

L.H. joystick controllers. Each valve solenoid is controlled by proximity switches via a relay.

To make the joystick contollers active the seat must first be locked in the forward or rear facing position, thereby closing either the seat forward proximity switch

Q

or seat rear proximity switch

R

. The operator must then raise forward the arm rests. Raising the R.H. arm rest closes the R.H. arm proximity switch

P

energising relay

F

and the R.H. isolation valve solenoid

H

, making the R.H. joystick controller active.

Similarly the L.H. joystick controller is made active when the

L.H. arm rest is raised forward.

When an arm rest is pushed back by the operator, the proximity switch in that arm rest will open and de-energise the relay and solenoid, servo pressure will be isolated and the joystick controller in that arm rest will be disabled.

Should the operator move the seat from the forward or rear facing position, the appropriate proximity switch will open and servo pressure to both joystick controllers will be isolated, both joystick controllers will be disabled.

The L.H. joystick houses a horn switch

S

. On some machine variants the joysticks also incorporate switches

U

and

V

for control of a hydraulic quickhitch, and an auxiliary changeover switch

W

, typically to select between jaw bucket and extending dipper operation.

Component Key:

Q

R

S

T

U

K

L

M

N

P

E

F

G

H

J

A

B

C

D

V

W

SA

Primary Fuse

Relay

Rear Horn Relay

Auxiliary Changeover Relay

Isolation Valve Relay — L.H. Joystick

Isolation Valve Relay — R.H. Joystick

Isolation Valve Solenoid — L.H. Joystick

Isolation Valve Solenoid — R.H. Joystick

Pump Dump Controller (Power Management ECU)

Throttle Position Sensor

Hydraulic Oil Temperature Sensor

Unloader Valve (HSC) Solenoid

Proximity Switch — L.H. Arm Rest

Proximity Switch — R.H. Arm Rest

Proximity Switch — Seat Forward

Proximity Switch — Seat Rear

Rear Horn Switch

Rear Horn Switch

Quickhitch Switch

Quickhitch Switch

Auxiliary Change-over Switch

Splice

Pump Dump Controller (Power Management ECU)

The electronic control unit is mounted in the engine compartment and is used to control engine hydraulic power.

When operating under conditions of high engine load and/or conditions of high hydraulic oil temperature (when operating hammer attachments for example), the pump dump controller

J

automatically activates the unloading valve (HSC) circuit, dumping the hydraulic oil flow from the secondary pump section (P2) to tank.

1 Engine Load Condition:

The pump dump controller

J

compares the ‘actual’ engine speed signal from the alternator stator with the engine speed

‘demanded’ signal from the throttle position sensor

K

.

If the engine speed should start to slow under conditions of high load, the pump dump controller

J

energises the unloader valve (HSC) solenoid

M

and illuminates an LED on the side console. The flow from the secondary pump section

(P2) is dumped to tank reducing the flow available to the hydraulic system, thereby reducing the load on the engine.

When the engine speed recovers the pump dump controller de-energises the unloader valve (HSC) solenoid

(extinguishing the LED on the side console), enabling the hydraulic system to operate normally.

The operating parameters are as follows:

a

At engine speeds below 1000 rpm, as determined by the throttle position sensor, the unloader valve (HSC) solenoid will always be energised.

b

At 1000 rpm the unloader valve (HSC) solenoid will be energised if the engine rpm falls more than 150 rpm below the ‘no load’ engine speed as determined by the throttle position sensor. The unloader valve (HSC) solenoid will de-energise when the engine rpm recovers to less than 25 rpm below the ‘no load’ engine speed as determined by the throttle position sensor.

c

At engine speeds greater than 1000 rpm, the unloader valve (HSC) solenoid energise and de-energise set points are increased by 10 rpm for every 100 rpm increase in engine speed.

2 Hydraulic Oil Temperature Condition:

The pump dump controller

J

monitors the hydraulic oil temperature via a sensor

L

fitted at the rear of the hydraulic oil tank.

If the oil temperature should reach 90°C, the pump dump controller

J

energises the unloader valve (HSC) solenoid

M

and illuminates an LED on the side console. The flow from the secondary pump section (P2) is dumped to tank reducing the flow available to the hydraulic system. The pump continues to circulate the oil around the neutral circuit and through the oil cooler until the oil temperature has reduced sufficiently. When the oil temperature has fallen to less than

70°C, the pump dump controller de-energises the unloader valve (HSC) solenoid (extinguishing the LED on the side console), enabling the hydraulic system to operate normally.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

45 — 7

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

45 — 7

Basic System Operation

Joystick Controllers — Description

The joystick controllers operate as direct operated pressure reducing valves and consist of a hand control lever, four pressure reducing valves and the housing. Each pressure reducing valve consists of a control spool, control spring, return spring and a plunger.

In neutral the control lever

5

is kept in the central position by the return spring

8

. Service ports

1

,

2

,

3

and

4

are connected to the tank port

T

via gallery

11

.

When the control lever

5

is operated, plunger

9

pushes against return spring

8

and control spring

7

. The control spring

7

moves the control spool

6

down-wards and closes the connection between the relevant service port and the tank port

T

. The service port is connected to the pressure port

P

via gallery

11

.

The control phase begins when the control spool

6

has found its balance between the force of the control spring

7

and the force which results from the hydraulic pressure in the selected port.

The interaction of the control spool

6

and control spring

7

enables the plunger

9

to produce pressure proportional to the position of the control lever

5

.

5

Hydraulic symbol

P T

9

1 2 3 4

11

8

7

6

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

9803/3280

Purchased from www.WorkshopManuals.co.uk

P T

A403930

Issue 1

Section D

45 — 8

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

45 — 8

Basic System Operation

Servo Pressure Supply Valve — Description

The servo pressure supply valve is fitted with a pressure regulating valve

1

, a pressure relief valve

2

and two solenoid valves

3

for servo pressure isolation.

The servo system is supplied from a single line tapped into the hydraulic pump feed at the excavator valve block. The pressure regulating valve

1

maintains servo pressure by regulating the incoming supply pressure. The valve is nonadjustable and is factory set with shims.

The pressure relief valve

2

is adjustable and limits the maximum pressure, protecting the valve block from overpressurisation by opening and allowing excess pressure to vent to tank.

Down stream of the pressure regulating valve is located the servo accumulator

4

with its associated non return valve.

The accumulator traps and stores servo pressure to enable the excavator spools to be operated for a limited period with a stopped engine. This allows the excavator end to be lowered safely to the ground should the engine stop.

The servo isolator solenoid valves

3

are energised by proximity switches on the drivers seat. When the seat arm rest is raised forward, the proximity switch closes and energises the relevant isolator solenoid, directing servo pressure to the particular joystick controller. When the arm rest is folded back the proximity switch opens and the isolation solenoid is de-energised, the isolation valve spool is spring returned to the closed position isolating the supply to the joystick controller.

9803/3280

Hydraulic symbol

P1 P2

1

T

PV

2

3

3

4

Purchased from www.WorkshopManuals.co.uk

A404750

Issue 1

Section D

47 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

47 — 1

Fault Finding

Introduction

The fault finding procedures are given in the form of flow charts. There are a number of charts, each one dedicated to a particular fault. The charts are designed to identify possible causes by performing checks and where applicable, specific tests. Having identified a cause the suggested remedy is given. The charts are designed to identify causes through a process of elimination, starting with the simplest, most easily rectified faults.

When fault finding note the following:

1

Make sure that the hydraulic fluid is at the correct working temperature (50 o

C, 122 o

F).

2

If hydraulic contamination is found be sure to remove

ALL debris, and if possible identify its origin. It may be part of a component from elsewhere in the hydraulic circuit.

3

Renew any seals such as ‘O’ rings when re-assembling hydraulic components.

Fault Finding Charts:

Chart A

— No Servo Controls (system fails to operate)

Chart B

— All Backhoe Services Slow to Operate

Chart C

— One Backhoe Service fails or is Slow to Operate

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

47 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

47 — 2

Fault Finding

Chart A — No Servo Controls (system fails to operate)

START

Does the system operate if the seat is locked in the opposite facing position?

Check that the arm rests are raised forward (i.e. not pushed back)

YES

Check the function of the seat mounted proximity switches and condition of associated wiring for damage. Repair or renew as applicable.

NO

Are the servo pressure isolation valve solenoid coils faulty?

NO

Are the relevant electrical fuses intact?

YES

Is the wiring to the servo pressure isolation valve solenoid coils intact?

YES

YES

NO

NO

Renew the solenoid coil(s).

Inspect and test all relevant wiring for damage and short circuits.

Repair as applicable. Renew the fuses.

Repair or renew as applicable.

Renew servo pressure isolation valve cartridge.

Refer to Servo Pressure Supply Valve

— Dismantling and Assembly.

Refer to Electrical Operation

— Joystick Controller.

A405600

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

47 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

47 — 3

Fault Finding

Chart B — All Backhoe Services Slow to Operate

START

Is the servo pressure low?

NO

Are the servo pressure isolation valves operating correctly? Remove the valve cartridges and check for signs of contamination or sticking.

YES

Are the joystick controls worn?

Check the condition of the universal joint mechanism on the joystick controllers.

YES

NO

Adjust as required.

Refer to Service Procedures

— Testing the Servo Pressure.

Clean and renew components as applicable.

Refer to Servo Pressure Supply Valve

— Dismantling and Assembly.

YES

Repair or renew as applicable.

Refer to Joystick Controllers —

Dismantling and Assembly.

NO

Is the load sense relief valve out of adjustment or defective?

NO

YES

Adjust, repair or renew as required.

Refer to Section E, Service

Procedures, Pressure Testing — Load

Sense Relief Valve.

Refer to Section E, Excavator Valve

— Dismantling and Assembly.

Is the flushing valve piston in the excavator valve inlet section blocked open (return to tank)?

YES

Clean and renew components as applicable.

Refer to Section E, Excavator Valve

— Dismantling and Assembly.

9803/3280

NO

Does the engine remain under load after the spools are returned to neutral?

Remove the flow regulator valve and check for signs of contamination or sticking. Check if the valve filter is clogged.

YES

Clean and renew components as applicable.

Refer to Section E, Excavator Valve

— Dismantling and Assembly.

A405670

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

47 — 4

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

47 — 4

Fault Finding

Chart C — One Backhoe Service fails or is Slow to Operate

START

Inspect the associated joystick controller valve capsule for signs of wear, damage or contamination.

Is the valve in good working order?

YES

Is the associated auxiliary relief valve

(ARV) out of adjustment or blocked open (return to tank)?

NO

YES

NO

Clean and renew components as applicable.

Refer to Joystick Controllers —

Dismantling and Assembly.

Adjust, repair or renew as required.

Refer to Section E, Service

Procedures, Excavator Valve,

Pressure Testing — ARV’s.

Refer to Section E, Excavator Valve

— Dismantling and Assembly.

Is the associated pressure compensator blocked?

Test the pressure compensator network.

YES

Clean and renew components as applicable.

Refer to Section E, Excavator Valve

— Dismantling and Assembly.

Refer to Section E, Service Procedures,

Excavator Valve, Pressure Compensator

Network — Testing.

NO

Will the service hold a load normally?

Inspect the associated load hold check valves and the service spool for signs

of wear, damage or contamination.

NO

Clean and renew components as applicable.

Refer to Section E, Excavator Valve

— Dismantling and Assembly.

Refer also to Section E, Hydraulics

Fault Finding, ‘One hydraulic service fails or is slow to operate’.

A405690

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

48 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

48 — 1

Service Procedures

Testing the Servo Pressure

TBA

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

50 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

50 — 1

Joystick Controllers

Removal and Replacement

!

DANGER

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

Note that the procedure shows the left hand joystick controller. The removal and replacement procedure for the right hand joystick controller is identical.

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the attachments to the ground and stop the engine.

Before attempting to remove a joystick controller, vent the pilot circuit accumulator hydraulic pressure as follows:

2

With the operator seat locked in the rear facing position and with the arm rests raised forward (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

3

Remove the screws

A

(4 off) and lift off the top retaining plate as shown.

4

Using a screwdriver, carefully prise out the plastic cap

B

. Remove the screws

C

(2 off) and take off the lower cover to reveal the connections at the valve block.

5

Disconnect the electrical harness connector for the joystick handle switches.

6

Disconnect all hydraulic hoses from the valve block and plug the ports to prevent ingress of dirt. Label each hose before disconnecting to ensure correct replacement. Plug hose ends to prevent ingress of dirt.

7

Carefully prise back the rubber gaiter

D

to reveal the fixing bolts (4 off) securing the valve to the arm rest.

Remove the fixing bolts and lift the valve assembly from the seat.

Replacement

Replacement is the reverse of the removal sequence.

Note:

All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adaptor.

D

C

B

A

A405620

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

50 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

50 — 2

Joystick Controllers

Dismantling and Assembly

7

3

8

A404780

1

2

6

4

5

9803/3280

Purchased from www.WorkshopManuals.co.uk

A404770

Issue 1

Section D

50 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

50 — 3

Joystick Controllers

Dismantling and Assembly

Dismantling

The illustration shown on the opposite page is intended as a guide to dismantling. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable.

Make sure that components are assembled in their original positions.

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Remove the joystick controller from the machine, refer to

Joystick Controller — Removal and Replacement

.

2

Carefully prise back the rubber gaiter

1

, loosen lock nut

2

and unscrew the handle

3

.

3

Unscrew the universal joint assembly

4

. Take care to keep all the shims

5

together.

4

Remove the retaining plate

6

. Carefully withdraw the regulating valve assemblies

7

from the valve body

8

.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Renew all ‘O’ rings and back-up rings.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

Torque Settings

Item

2

4

Nm

50

kgf m

40 4.1 29.5

5.1

lbf ft

36.9

Regulating Valve Assemblies

Each of the regulating valve assemblies

7

can be removed as shown. Care must be taken to ensure that the spool is not damaged when removing it from the valve body. Note that all spools are similar in appearance but must not be interchanged as they are matched to their bores. All spools have the same centring and sealing components.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

51 — 1

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

51 — 1

Servo Pressure Supply 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

!

DANGER

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

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the attachments to the ground and stop the engine.

Before attempting to remove the valve, vent the pilot circuit accumulator hydraulic pressure as follows:

2

With the operator seat locked in the rear facing position and with the arm rests raised forward (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

3

Working underneath the rear of the machine as shown, disconnect the electrical harness connectors

A

at the solenoids. Label each connector before disconnecting to ensure correct replacement.

4

Disconnect all hydraulic hoses from the valve block and plug the ports to prevent ingress of dirt. Label each hose before disconnecting to ensure correct replacement. Plug hose ends to prevent ingress of dirt.

5

Take hold of the valve assembly, loosen and remove the fixing bolts

B

securing the valve to the chassis. Lift the valve assembly from the machine.

Replacement

Replacement is the reverse of the removal sequence.

After replacement check the valve pressure settings. Refer to

Service Procedures — Testing the Servo Pressure

.

Note:

All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adaptor.

B

B

A

A405610

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

51 — 2

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

51 — 2

Servo Pressure Supply Valve

Dismantling and Assembly

1

5

2A

2

3

2B

4

7

6

9803/3280

Purchased from www.WorkshopManuals.co.uk

A404760

Issue 1

Section D

51 — 3

www.WorkshopManuals.co.uk

Controls

Precision Control (Servo)

Section D

51 — 3

Servo Pressure Supply Valve

Dismantling and Assembly

Dismantling

The illustration shown on the opposite page is intended as a guide to dismantling. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable.

Make sure that components are assembled in their original positions.

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Remove the servo pressure supply valve from the machine, refer to

Servo Pressure Supply Valve —

Removal and Replacement

.

Note:

The illustration depicts a complete strip down, but to carry out specific servicing/repairs, e.g. renewal of one of the solenoids, it is only necessary to dismantle the relevant components.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Renew all ‘O’ rings and back-up rings.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

Torque Settings

6

7

Item

1

2

3

4

2A

2B

5

Nm kgf m lbf ft

100 10.2 73.8

10 1 7.4

10

30

1

3

7.4

22.1

100 10.2 73.8

100 10.2 73.8

150 15.3

110.6

100 10.2 73.8

15-20 1.5-2 11-14.8

Accumulator

The accumulator

1

can be removed as shown. Take great care when handling the accumulator, the unit is pre-charged with nitrogen gas and further dismantling of the accumulator should not be attempted. The adaptor assembly

3

incorporates a non-return valve with a spring and ball as shown.

Regulating Valve Assembly

The regulating valve assembly

5

can be removed as shown.

The valve is non-adjustable and is factory set with shims.

Take care to keep all the shims together.

Pressure Relief Valve

The pressure relief valve

6

can be removed as shown.

Solenoid Isolation Valves

The solenoid isolation valves

7

can be removed as shown. It is possible to remove the valve cartridges for cleaning or resealing without removing the complete valve from the machine. If there is evidence of damage to the valve or its seat caused by debris then the cartridge must be renewed.

Note:

If removing components from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. With the operator seat locked in the rear facing position and with the arm rests raised forward

(for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

60 — 1

www.WorkshopManuals.co.uk

Controls

Control Rods and Linkages

Section D

60 — 1

Dismantling and Assembly

Loader Valve Controls

G

D

F

K

Locking

Pin

E

H

X

C

A404660

K

J

A

B

A404500

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section D

60 — 2

www.WorkshopManuals.co.uk

Controls

Control Rods and Linkages

Section D

60 — 2

Dismantling and Assembly

Loader Valve Controls

The illustration on the adjacent page shows the control rods and linkages for the loader control valve and is intended as a guide to the dismantling and assembly.

Dismantling

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key. Disconnect the battery.

2

Working in the cab, remove the console panels surrounding the loader levers as shown at

Z

.

3

Uncouple the transmission dump switch electrical connector and remove the wires from the connector.

Use a screwdriver to release the wires/pins from the connector, alternatively cut the wires and re-solder on assembly.

4

Remove the control lever knobs and gaiters.

5

Disconnect the control rods from the loader valve spools. Remove the bolts securing the complete lever assembly to the chassis and withdraw the control levers and mounting bracket through the floor aperture.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Bolt the mounting bracket

A

to the chassis.

2

Fit the rubber cover

B

over the mounting bracket, make sure it is fitted the correct way round. Do not fix it to the floor at this stage.

3

Bolt the mounting plate

C

to mounting bracket as shown.

4

Assemble the loader lever

D

and auxiliary lever

E

together, with the washers and retaining clip as shown.

5

Fit the control rods

F

,

G

and

H

to the lever assembly.

Ensure that the locking flats

X

are at the top.

Note:

If necessary, loosen the lock nuts and rotate the end fittings to give equal amounts of adjustment (thread) at each end of the control rod.

6

Fit the lever assembly to the mounting plate

C

as shown, do not tighten the bolt

J

at this stage.

7

Thread the control rods through the rubber cover

B

and connect them to the loader valve spools.

8

Adjust the control rods as necessary, see

Adjustment

.

After the control rods are adjusted fit the gaiters over the control levers.

9

Thread the transmission dump switch cable through the loader control lever and fit the wires/pins into the electrical connector. Couple the connector to the chassis harness and fit the control lever knobs.

10

Connect the battery, check that the controls and transmission dump switch operate correctly.

11

Refit the rubber cover

B

and the console panels around the loader levers.

Adjustment

1

Fit the control lever locking pin

K

as shown, tighten bolt

J

when aligned.

Note:

If there is no lever locking pin with the machine use a suitable diameter metal bar.

2

Adjust the control rods

F

and

G

until the locking pin is a sliding fit, then tighten the control rods lock nuts.

Note:

Make sure there is an equal amount of thread at each end of the control rod.

3

Adjust the auxiliary control rod

H

until the auxiliary lever

E

aligns with loader lever

D

, then tighten the control rod lock nuts.

4

Remove the lever locking pin

K

.

Z

A394410

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

61 — 1

www.WorkshopManuals.co.uk

Controls

Control Rods and Linkages

Section D

61 — 1

Dismantling and Assembly

Excavator Valve Controls (JCB + Pattern)

F

G

J

Locking

Pin

L

9803/3280

H

H

A

K

E

D

C

B

Purchased from www.WorkshopManuals.co.uk

A404810

Issue 1

Section D

61 — 2

www.WorkshopManuals.co.uk

Controls

Control Rods and Linkages

Section D

61 — 2

Dismantling and Assembly

Excavator Valve Controls

The illustration on the adjacent page shows the control rods and linkages for the excavator control valve and is intended as a guide to the dismantling and assembly. Note JCB + pattern controls shown.

Dismantling

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms, move the excavator to the R.H. side of the machine and lower to the ground. Switch OFF the engine and remove the starter key. Disconnect the battery.

2

Working in the cab, remove the console panels surrounding the excavator levers as shown at

Z

.

3

Uncouple the rear horn switch electrical connector and remove the wires from the connector. Use a screwdriver to release the wires/pins from the connector, alternatively cut the wires and re-solder on assembly.

4

Remove the control lever knobs and gaiters.

5

Disconnect the control rods from the excavator valve spools. Remove the bolts securing the complete lever assembly to the excavator valve mounting plate and withdraw the control levers and mounting bracket through the floor aperture.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Bolt the mounting bracket

A

to the excavator valve mounting plate.

2

Assemble the pivot levers

B

and spacers

C

to the mounting bracket and insert the pivot shaft

D

. Fit the short control rods

E

(2 off) to the pivot lever assembly as shown.

3

Assemble the excavator levers

F

and

G

to the mounting bracket together with the universal joints

H

. Fit the longer control rods

J

(4 off) to the lever assembly as shown.

Note:

If necessary, loosen the lock nuts and rotate the end fittings to give equal amounts of adjustment (thread) at each end of the control rod.

4

Connect the control rods to the excavator valve spools with the clevis pins

K

.

5

Adjust the control rods as necessary, see

Adjustment

.

After the control rods are adjusted fit the gaiters over the control levers.

6

Thread the rear horn switch cable through the control lever and fit the wires/pins into the electrical connector.

Couple the connector to the chassis harness and fit the control lever knobs.

7

Connect the battery, check that the controls and rear horn switch operate correctly.

8

Refit the console panels around the excavator levers.

Adjustment

1

Fit the control lever locking pin

L

as shown.

Note:

If there is no lever locking pin with the machine use a suitable diameter metal bar.

2

Adjust the control rods until the locking pin is a sliding fit, then tighten the control rods lock nuts.

Note:

Make sure there is an equal amount of thread at each end of the control rod.

3

Remove the lever locking pin

L

.

Z

A394410

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section D

70 — 1

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

70 — 1

Removal and Replacement

Cab Heater Controls

X

Y

S

R

C

R

T

X

Z

D

9803/3280

0 —

1

—

2

—

E

A404491

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

70 — 2

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

70 — 2

Removal and Replacement

Cab Heater Controls

The cab heater controls

A

and associated cables are housed in the R.H. side console as shown.

There are two control cables which operate the re-circulation vent and the hot water valve. Both the cables can be accessed by removing the side console instrument panel.

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Remove the fixing

B

at the top of the instrument panel and carefully lift the panel forward to reveal the connections at the back.

3

Disconnect the temperature control cable

C

by releasing the cable outer sheath from the clips

R

at each end, and unhooking the cable from the water valve lever

S

and from the pin

T

at the control knob.

4

Disconnect the re-circulation vent cable

D

by releasing the cable outer sheath from the clips

X

at each end, and unhooking the cable from the vent

Y

and from the pin

Z

at the control knob.

Replacement

Replacement is the reverse of the removal sequence.

After fitting the cables, operate the heater controls and check that they function correctly.

A

B

A394410

Adjustment

If the control cable

C

is not correctly assembled it is possible that the heater cannot be turned fully off.

To ensure that the heater can be turned fully OFF, the temperature control cable

C

should be adjusted so that the water valve will close FULLY within the range of movement of the control knob as follows:

1

Set the water valve control lever

S

to the fully closed position.

2

Turn the heater control knob

E

a small amount clockwise from the closed position, i.e. a fraction before the cold position on the decal as shown.

3

Tighten the cable clips

R

to clamp the cable outer sheath.

4

Check the heater control range of movement and that the water valve can be fully closed by turning the knob.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

71 — 1

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

71 — 1

Removal and Replacement

Stabiliser Controls

F

H

G

A404700

E

D

B

C

9803/3280

A404730

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

71 — 2

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

71 — 2

Removal and Replacement

Stabiliser Controls

The stabiliser controls

A

and associated cables are housed in the R.H. side console as shown.

There are two control cables which operate the R.H. and

L.H. stabiliser control valves on the excavator valve block.

Note the routing of the existing cables and route the new cable(s) in the same way.

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Working under the machine at the excavator valve, undo the locknut

B

. Remove the screws

C

and slide back the housing

D

to reveal the clevis as shown.

Remove the clevis pin

E

to release the cable from the spool.

3

Feed the end of the cable back underneath the cab to the rear wheel arch on the R.H. side of the machine and release the cable from the clamp assembly at position

X

as shown.

4

Working in the cab, remove the fixings

F

from around the base of the control levers and carefully withdraw the lever assembly from the side console to reveal the cables connected on the underside.

5

Remove the clamp

G

securing the cables to the bracket. Remove the spring clip and clevis pin

H

to release the cable.

6

From inside the side console, carefully pull the cable up into the cab through the aperture in the cab floor.

Replacement

Replacement is the reverse of the removal sequence.

After fitting the cable(s), operate the controls and check that the stabilisers function correctly.

A

A394410

X

A405180

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section D

72 — 1

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

72 — 1

Removal and Replacement

Boom Lock Cable

X

D

A405180

A

A394410

9803/3280

C

B

2

3

6

5

1

4

A404510

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

72 — 2

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

72 — 2

Removal and Replacement

Boom Lock Cable

The boom lock control

A

and associated cable is housed in the R.H. side console as shown.

Note the routing of the existing cable and route the new cable in the same way.

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Working at the boom, remove the cable ball stud

B

from the boom lock casting.

3

Loosen the lock nut and disconnect the bulkhead fitting

C

from the bracket. Feed the end of the cable back underneath the cab to the rear wheel arch on the R.H.

side of the machine and release the cable from the clamp assembly at position

X

as shown. Remove the spring clip

D

from the outer sleeve.

4

Working in the cab, unscrew the knob and lock nut from the boom lock control

A

. Remove the fixings from the side console panel and carefully lift up the rear corner of the side console panel over the boom lock control outer sleeve.

5

With the rear corner of the side console panel lifted up, carefully pull the boom lock cable up into the cab through the aperture in the cab floor.

Replacement

Replacement is the reverse of the removal sequence.

1

After fitting the cable, with the control knob pressed down adjust the bulkhead fitting

C

to take up any slack in the cable. The cable should be tight but must not lift the boom lock from its fully down position.

2

Operate the boom and check that the boom lock will engage and disengage correctly using the control knob in the cab. Check the boom stop setting, see

Boom

Stop Setting

.

Boom Stop Setting

The boom stop block should be set as follows:

1

Lightly secure the boom stop block

1

in its lowest position.

2

Raise the boom lock

2

using the control knob in the cab.

3

Fully raise the boom (i.e. the boom ram fully retracted) and engage the boom lock using the control knob in the cab.

4

With the engine switched OFF, operate the excavator control levers several times to vent any resisdual pressure from the boom ram.

5

Adjust the boom stop block

1

until there is 3 mm (1/8 in.) gap between the stop and the boom profile as shown at

3

.

6

Tighten clamping bolt

4

. Tighten grubscrew

5

and lock nut

6

.

7

Switch ON the engine. Fully raise the boom (i.e. the boom ram fully retracted) and raise the boom lock using the control knob in the cab.

8

If the boom lock does not release readjust the stop block as follows:

a

Loosen the lock nut

6

and slacken the grubscrew

5

a further half turn.

b

Loosen clamping bolt

4

and reposition the stop block. Retighten bolt

4

and lock the grubscrew.

9

Operate the boom and check that the boom lock will engage and disengage correctly using the control knob in the cab.

Torque Settings

Item

E

Nm

476

kgf m

48

lbf ft

352

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

73 — 1

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

73 — 1

Removal and Replacement

Engine Throttle Cable

D

C

A404690

K

J

K

E

F

G

E

9803/3280

A404680

Purchased from www.WorkshopManuals.co.uk

A404670

Issue 1

Section D

73 — 2

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

73 — 2

Removal and Replacement

Engine Throttle Cable

The engine throttle cable is routed from the L.H. side of the engine compartment to connect with the footpedal

A

at the engine compartment bulkhead, and to the hand throttle lever

B

housed in the R.H. side console as shown.

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Open the bonnet and remove the engine side covers.

3

At the L.H. side of the engine compartment, disconnect the throttle cable by loosening the lock nut

C

and unhooking the cable from the fuel injector pump lever

D

as shown. Feed the end of the cable back across the engine compartment to the bulkhead on the R.H. side.

4

Working at the R.H. side of the engine compartment at the bulkhead, remove the screws

E

and ease back the rubber bulkhead cover to reveal the end of the footpedal lever as shown. Remove the nut

F

and disconnect the cable pivot block from the footpedal.

Loosen the lock nut

G

and release the cable from the bracket. Feed the cable back underneath the cab to the rear wheel arch on the R.H. side of the machine.

5

Working in the cab, remove the fixing

H

at the top of the instrument panel and carefully lift the panel forward to reveal the hand throttle lever and mounting bracket assemby

J

inside the side console as shown.

6

Remove the hand throttle lever knob. Remove the screws

K

, taking hold of the hand throttle lever assembly withdraw the handle through the slot in the panel.

7

From inside the side console, carefully pull the cable up into the cab through the aperture in the cab floor.

Replacement

Replacement is the reverse of the removal sequence.

After fitting the cable, operate the hand and foot throttle controls and check that they function correctly.

A

B

H

A394410

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section D

74 — 1

www.WorkshopManuals.co.uk

Controls

Control Cables

Section D

74 — 1

Removal and Replacement

Auxiliary Footpedal Cable

The auxiliary footpedal control

A

is mounted in the cab floor as shown. The cable operates the auxiliary control valve located adjacent to the excavator valve. The cable is accessible underneath the rear L.H. corner of the cab.

Note the routing of the existing cable and route the new cable in the same way.

Removal

1

Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.

2

Working at the rear of the machine at the auxiliary valve, undo the locknut

B

. Remove the screws

C

and slide back the housing

D

to reveal the clevis as shown.

Remove the clevis pin

E

to release the cable.

3

At the footpedal remove the U-clamp

F

securing the cable to the bracket. Remove the spring clip

G

to release the cable. If the cable is to be replaced, remove and retain the microswitch operating tab

H

from the old cable as shown.

Replacement

Replacement is the reverse of the removal sequence.

A

A394410

C

B

D

E

G

F

9803/3280

H

A404710

Purchased from www.WorkshopManuals.co.uk

A404720

Issue 1

i

Section E

www.WorkshopManuals.co.uk

Hydraulics

Section E i

Contents

Service Tools

Page No.

1 — 1

Technical Data

Hydraulic Pumps

Fixed Flow

Variable Flow

Relief Valve Pressures

Loader Valve — Fixed Flow

Loader Valve — Precision Control (Servo)

— Machines up to serial no. 931159

— Machines from January 2003

Loader Valve — Variable Flow

Excavator Valve — Fixed Flow

Excavator Valve — Precision Control (Servo)

— Machines up to serial no. 931159

— Machines from January 2003

Auxiliary Valve — Fixed Flow

Smooth Ride System

Basic System Operation

Component Location and Neutral Circuit Descriptions

Fixed Flow — Single Pump

— Double Pump

Variable Flow

Introduction to Hydraulic Schematic Symbols

Circuit Schematics

Fixed Flow

Variable Flow

Precision Control (Servo)

— Machines up to serial no. 931159

— Machines from January 2003

2 — 1

2 — 3

2 — 4

2 — 5

2 — 5A

2 — 7

2 — 8

2 — 10

2 — 10A

2 — 11

2 — 13

3 — 1

3 — 3

3 — 7

3 — 10

3 — 20

3 — 26

3 — 31

3 — 33

Circuit Descriptions

Hydraulic Pump — Fixed Flow

Single Pump Operation

Double Pump Operation

Hydraulic Pump — Variable Flow

Operation

Pressure/Flow Regulator Valve

Loader Valve

Manual Control

— Neutral Circuit

— Unloader Operation

— Hydraulic Speed Control (HSC)

— Load Hold Check Valves Operation

— Arms Lower

— Float

— Auxiliary Relief Valve (ARV) Operation

— Main Relief Valve (MRV) Operation

5 — 1

5 — 1

5 — 3

5 — 5

6 — 1

6 — 1

6 — 3

6 — 5

6 — 7

6 — 7

6 — 9

6 — 11

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 4*

ii

Section E

www.WorkshopManuals.co.uk

Hydraulics

Section E ii

Contents

Loader Valve — Variable Flow

Operation

Priority Inlet Section Operation

Auxiliary Spool

Loader Shovel Spool

Loader Lift Spool

Shuttle Valve Signal Network

Excavator Valve

Manual Control

— Neutral Circuit

— Load Hold Check Valves Operation

— One Way Restrictor Operation

— Slew Operation

— Slew ARV and Anti Cavitation Operation

— Auxiliary Relief Valve (ARV) Operation

— Pilot Operated Pressure Relief Valve Operation

— Hydraclamp Valve Operation

Precision Control (Servo)

— Machines up to serial no. 931159

Hydraclamp Valve Operation

— Machines from January 2003

Smooth Ride System

Hose Burst Protection Valves (if fitted)

Boom & Dipper Operation

Loader Operation

Page No.

8 — 13

8 — 17

8 — 18

10 — 1

11 — 1

11 — 5

8 — 1

8 — 3

8 — 5

8 — 5

8 — 7

8 — 7

8 — 9

8 — 11

7 — 1

7 — 2

7 — 4

7 — 5

7 — 6

7 — 7

Fault Finding

Hydraulic System

Fixed Flow

Variable Flow

Smooth Ride System

15 — 1

15 — 10

15 — 12

Service Procedures

Hydraulic Contamination

Fixed Flow Pumps

Flow and Pressure Testing

Variable Flow Pumps

Flow and Pressure Testing

Regulator Valve Adjustment

Renewing Drive Shaft Seal

Shuttle Valve Signal Network — Testing

Loader Valve — Pressure Testing

Main Relief Valve (MRV)

Unloader Valve

Hydraulic Speed Control (HSC)

Auxiliary Relief Valves (ARV’s)

Excavator Valve — Pressure Testing

Auxiliary Relief Valves (ARV’s)

20 — 1

21 — 1

22 — 1

22 — 5

22 — 7

22 — 8

23 — 1

23 — 2

23 — 3

23 — 5

23 — 9

Excavator Valve — Precision Control (Servo)

— Machines up to serial no. 931159

Pressure Testing —

Load Sense Drain Regulator and Relief Valve 23 — 10

9803/3280 Issue 4*

Purchased from www.WorkshopManuals.co.uk

Section E iii

www.WorkshopManuals.co.uk

Hydraulics

Section E iii

Contents Page No.

Excavator Valve — Precision Control (Servo)

— Machines from January 2003

Pressure Testing — Load Sense Relief Valve 23 — 11

Pressure Compensator Network — Testing 23 — 12

Ram Creep Tests — All Services

Quick Release Couplings

24 — 1

25 — 1 Connecting & Disconnecting

Smooth Ride System

Charging/Discharging the Accumulator

Hose Burst Protection Valves (if fitted)

26 — 1

Checking

Lowering a Load — In a Failure Condition

Pressure Testing — Loader Lift Ram

27 — 1

27 — 1

27 — 2

Main Pump

Fixed Flow

Removal and Replacement

Dismantling and Assembly

Variable Flow

Dismantling and Assembly

Loader Valve — Fixed Flow

Removal and Replacement

Manual Control

Dismantling and Assembly

Main Relief Valve (MRV)

Auxiliary Relief Valves (ARV’s)

Unloader Valve

Standard Spool — Manual

Float Spool — Manual

Electric Detent Spool — Manual

Bolt on Auxiliary Spool Section

— Auxiliary Relief Valves

Precision Control (Servo)

— Machines from January 2003

Standard Spool

Electric Detent Spool

Mechanical Detent Spool

Loader Valve — Variable Flow

Removal and Replacement

Dismantling and Assembly

Priority Inlet Section

Auxiliary Spool

Loader Shovel Spool

Loader Lift Spool

Fitting Spool Seal

30 — 1

31 — 1

35 — 1

55 — 1

55 — 2

55 — 4

55 — 6

55 — 8

55 — 10

50 — 1

50 — 6

50 — 8

50 — 10

50 — 12

50 — 14

50 — 16

50 — 24

50 — 26

51 — 1

51 — 3

51 — 5

51 — 7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 4*

Section E iv

www.WorkshopManuals.co.uk

Hydraulics

Section E iv

Contents

Excavator Valve

Removal and Replacement

Manual Control

Variable Flow

Precision Control (Servo)

Dismantling and Assembly

Manual Control

— Auxiliary Relief Valves (ARV’s)

— Hydraclamp Valve (Sideshift Machines)

— Hoses and Pipes

Precision Control (Servo)

— Machines up to serial no. 931159

Drain Regulator and Relief Valve

Hydraclamp Valve

— Machines from January 2003

Flow Regulator Valve

Load Sense Relief Valve

Auxiliary Relief Valves (ARV’s)

Anti-cavitation Valve

Hose Burst Protection Valves

(if fitted)

Removal and Replacement

Dismantling and Assembly

Hydraulic Rams

Removal and Replacement

Loader Lift Ram

Loader Shovel Ram

Slew Ram

Stabiliser Ram — Sideshift

Stabiliser Ram — Centremount

Dipper Ram

Bucket Crowd Ram

Boom Ram

Dismantling and Assembly

Loader Lift Ram

Loader Shovel Ram

Boom Ram

Bucket Ram

Stabiliser Ram

Dipper Ram

Slew Ram

Power Sideshift Ram

JCB Ram Sealing Procedure

Page No.

62 — 1

62 — 3

62 — 5

62 — 20

62 — 22

62 — 23

62 — 24

62 — 25

60 — 1

60 — 4

60 — 6

61 — 1

61 — 3

61 — 5

61 — 6

70 — 1

70 — 2

85 — 1

85 — 1

85 — 1

85 — 1

85 — 1

86 — 1

87 — 1

88 — 1

89 — 1

75 — 1

76 — 1

77 — 1

78 — 1

78 — 3

79 — 1

80 — 1

81 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 4*

Section E

v

www.WorkshopManuals.co.uk

Hydraulics

Section E

v

Contents

Hydraulic Oil Cooler

Removal and Replacement

Smooth Ride System

Accumulator

Removal and Replacement

Dismantling and Assembly

Page No.

95 — 1

96 — 1

96 — 2

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

1 — 1 Service Tools

Section E

1 — 1

S267300

Hydraulic Circuit Pressure Test Kit

892/00253

:892/00201

:892/00202

:892/00203

:892/00254

993/69800

892/00706

Pressure Test Kit

Replacement Gauge 0-20 bar (0-300 lbf/in

2

Replacement Gauge 0-40 bar (0-600 lbf/in

2

Replacement Hose probe 892/00706)

Test Probe

)

)

Replacement Gauge 0-400 bar (0-6000 lbf/in

2

)

Seal Kit for 892/00254 (can also be used with

S188121

S188131

Pressure Test ‘T’ Adapters

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point

816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point

816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point

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

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

892/00265 1 in M BSP x 1 in F BSP x Test Point

Pressure Test Adapters

892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point

892/00257 1/2 in BSP x Test Point

892/00258 5/8 in BSP x Test Point

816/15118 3/4 in BSP x Test Point

892/00259 1 in BSP x Test Point

892/00260 1.1/4 in BSP x Test Point

892/00261 5/8 in UNF x Test Point

S200141

Flow Test Equipment

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 — 100 l/min (0 — 22 UK gal/min)

892/00293 Connector Pipe

892/00270 Load Valve

1406/0021 Bonded Washer

1604/0006 Adapter 3/4 in M x 3/4 in M BSP

1612/0006 Adapter 3/4 in F x 3/4 in M BSP

892/00271 Adapter 3/4 in F x 5/8 in M BSP

892/00272 Adapter 5/8 in F x 3/4 in M BSP

816/20008 Adapter 3/4 in F x 1/2 in M BSP

892/00275 Adapter 1/2 in F x 3/4 in M BSP

892/00276 Adapter 3/4 in F x 3/8 in M BSP

892/00277 Adapter 3/8 in F x 3/4 in M BSP

892/00273 Sensor Head 0 — 380 l/min

892/00294 Connector Pipe

1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078 Connector 1 in F x 1 in F BSP

1604/0008 Adapter 1 in M x 1 in M BSP

1606/0012 Adapter 1 in M x 3/4 in M BSP

816/20013 Adapter 3/4 in F x 1 in M BSP

9803/3280

Purchased from www.WorkshopManuals.co.uk

S188151

Issue 1

Section E

1 — 2 Service Tools

Section E

1 — 2

892/00881 Valve Spool

Seal Fitting Tool

S261220

Components for Valve Block A.R.V. Testing

For 4CX Variable Flow machines use 25/201103

892/00309

1 : 892/00340

2 : 892/00341

3 : 993/68300

4 : 892/00343

5 : 892/00345

6 892/00335

A.R.V. Pressure Test Kit

Test Block Body

Setting Body

Adjusting Pin

Spanner

Anti-cavitation Lock Out Bung

A.R.V. Cartridge Removal Tool

4

6

2

1

Hand Pump Equipment

892/00223 Hand Pump

892/00137 Micro-bore Hose 1/4 in BSP x 3 metres

892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point

892/00706 Test Probe

892/00278 Gauge 0 — 40 bar (0 — 600 lbf/in 2 )

892/00279 Gauge 0 — 400 bar (0 — 6000 lbf/in 2 )

S193850

Bonded Washers

1406/0011

1406/0018

1406/0014

1406/0021

1406/0029

1/4 in. BSP

1/2 in. BSP

5/8 in. BSP

3/4 in. BSP

1.1/4 in. BSP

5

3

S196700

S188140

Male Adapters — BSP x NPT (USA only)

816/00439 3/8 in. x 1/4 in.

816/00440 1/2 in. x 1/4 in.

816/15007 3/8 in. x 3/8 in.

816/15008 1/2 in. x 3/8 in.

Male Adapters — BSP x BSP

1606/0003 3/8 in. x 1/4 in.

1604/0003 3/8 in. x 3/8 in.

892/00071 3/8 in. x 3/8 in. taper

1606/0004 1/2 in. x 1/4 in.

1606/0007 1/2 in. x 3/8 in.

1604/0004 1/2 in. x 1/2 in.

1606/0017 5/8 in. x 1/2 in.

1606/0008 3/4 in. x 3/8 in.

1606/0009 3/4 in. x 1/2 in.

1604/0006 3/4 in. x 3/4 in.

1606/0012 3/4 in. x 1 in.

1606/0014 3/4 in. x 1.1/4 in.

1606/0015 1 in. x 1.1/4 in.

S193860

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

1 — 3 Service Tools

Section E

1 — 3

Female Cone Blanking Plug

892/00055 1/4 in. BSP

892/00056 3/8 in. BSP

892/00057 1/2 in. BSP

892/00058 5/8 in. BSP

892/00059 3/4 in. BSP

892/00060 1 in. BSP

S193870

Male Cone Blanking Cap

816/00294 1/4 in. BSP

816/00189 3/8 in. BSP

816/00190 1/2 in. BSP

816/00197 5/8 in. BSP

816/00196 3/4 in. BSP

816/00193 1 in. BSP

S193880

892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B)

892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051 1 in. BSP (A) x 1/4 in. BSP (B)

816/50005 1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096 3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017 1 in. BSP (A) x 1 in. BSP (B)

992/09100 Excavator Spool Clamp

892/00011 Spool Clamp

S193890

Female Connectors

892/00074 3/8 in. BSP x 3/8 in. BSP

892/00075 1/2 in. BSP x 1/2 in. BSP

892/00076 5/8 in. BSP x 5/8 in. BSP

892/00077 3/4 in. BSP x 3/4 in. BSP

S193900

Hexagon Spanners for Ram Pistons and End Caps

992/09300 55mm A/F

992/09400 65mm A/F

992/09500 75mm A/F

992/09600 85mm A/F

992/09700 95mm A/F

992/09900 115mm A/F

992/10000 125mm A/F

9803/3280

S216210

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

1 — 4

Service Tools

Section E

1 — 4

892/00334 Ram Seal Fitting Tool

S216250

20mm

7mm

11o

10mm

5mm

R

3m m

110mm

175mm

R 1.4mm

3o

892/01027 Piston Seal Assembly Tool

338500

892/00948 Charging Kit (without gauge)

892/00949 Gauge

S308271

9803/3280

S338410

Ram Seal Protection Sleeves

892/01016 For 25 mm Rod Diameter

892/01017 For 30 mm Rod Diameter

892/01018 For 40 mm Rod Diameter

892/01019 For 50 mm Rod Diameter

892/01020 For 50 mm Rod Diameter (slew ram)

892/01021 For 60 mm Rod Diameter

892/01022 For 60 mm Rod Diameter (slew ram)

892/01023 For 65 mm Rod Diameter

892/01024 For 70 mm Rod Diameter

892/01025 For 75 mm Rod Diameter

892/01026 For 80 mm Rod Diameter

892/00167 For 90 mm Rod Diameter

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 1

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 1

Hydraulic Pumps

*

Fixed Flow

Model/Reference

Mounting

Theoretical displacement:

Pump section 1 (mounting flange end)

Pump section 2

Double pump/4070H

Gearbox

33

23

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min UK

Pump section 1 (mounting flange end)

Pump section 2

65.3

45.5

14.4

10.0

Maximum speed @ pressure P1

Minimum speed @ pressure P1

3000 rev/min

500 rev/min

Approximate Weight 24kg (53 lbs)

2.01

1.40

17.2

12.0

*

Model/Reference

Mounting

Double pump/83103

Gearbox

Theoretical displacement:

Pump section 1 (mounting flange end)

Pump section 2

36

26

2.19

1.59

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min UK

Pump section 1 (mounting flange end) 71.3

15.7

Pump section 2

Maximum speed @ pressure P1

Minimum speed @ pressure P1

Approximate Weight

51.5

3000 rev/min

500 rev/min

23.8kg (52 lbs)

11.3

18.8

13.5

*

Model/Reference

Mounting

Theoretical displacement:

Pump section 1 (mounting flange end)

Double pump/7441N

Gearbox

41 2.50

Pump section 2 26 1.59

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min UK

Pump section 1 (mounting flange end)

Pump section 2

Maximum speed @ pressure P1

81.2

51.5

3000 rev/min

17.9

11.3

Minimum speed @ pressure P1

Approximate Weight

500 rev/min

24.5kg (54 lbs)

21.5

13.5

*

Model/Reference Double pump/4071F

Mounting

Theoretical displacement:

Pump section 1 (mounting flange end)

Pump section 2

Gearbox

41

29

2.50

1.77

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min UK

Pump section 1 (mounting flange end)

Pump section 2

Maximum speed @ pressure P1

Minimum speed @ pressure P1

Approximate Weight

81.2

57.4

3000 rev/min

500 rev/min

24.5kg (54 lbs)

17.9

12.6

21.5

15.1

continued……..

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

2 — 2

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 2

Hydraulic Pumps

*

Fixed Flow (continued)

Model/Reference

Mounting

Theoretical displacement:

Pump section 1 (mounting flange end)

Pump section 2

Approximate Weight

Double pump/PGP620/Common outlet

Gearbox

29

23

1.77

1.40

Flow at 2200 rev/min and system pressure (90% min displacement):

litres/min UK

Pump section 1 (mounting flange end)

Pump section 2

57.4

45.5

12.6

10.0

Maximum speed @ pressure P1

Minimum speed @ pressure P1

3000 rev/min

500 rev/min

24kg (53 lbs)

15.1

12.0

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

2 — 3

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 3

Hydraulic Pumps

Variable Flow

Type

Reference

*

Mounting

Load Sense Pressure (in neutral position)

Load sense pressure relief Valve (if fitted)

Stand-by Pressure

Maximum Hydraulic Stall Pressure

460001 to 472554 without relief valve

460001 to 472554 with relief valve and all from 472555

Maximum Displacement

Flow at 2200 rev/min and 2500 lb/in

2 pressure †

— minimumum acceptable flow rate (new or rebuilt pump)

— minimumum acceptable flow rate (used pump)

Flow in the Load Sense Line at 2200 rev/min (no pressure)

Weight

Variable Displacement

A10VO — 978753

Gearbox

Maximum permitted — 5 bar; 72.5 lbf/in

2

230 bar; 3335 lbf/in

2

20 bar; 290 lbf/in

2

232 bar; 3364 lbf/in

270 bar; 3915 lbf/in

74cc/rev; 4.5 in

3

2

2

/rev

75 -80 litres/min; 16.5 — 17.6 UK gal/min

70 — 75 litres/min; 15.4 — 16.5 UK gal/min

1 — 5 litres/min; 0.22 — 1.1 UK gal/min

TBAkg (TBA lbs)

† Note:

It is not possible to test full pump flow at system pressure, figures quoted give a ‘snapshot’ indication of pump performance. For more detail refer to

Service Procedures, Variable Flow Pumps — Flow and Pressure Testing

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

2 — 4

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 4

Relief Valve Pressures

Loader Valve — Fixed Flow

Main Relief Valve (M.R.V.)

Unloader Valve

Auxiliary Relief Valves (A.R.V.)

Loader

Shovel Ram Head Side

Shovel Ram Rod side

bar

236 — 241

207 — 214

172 — 179

310 — 317

kgf/cm 2

240 — 245

207 — 211

176 — 183

316 — 323

lbf/in 2

3420 — 3500

3000 — 3100

2500 — 2600

4500 — 4600

Note

: Instructions for pressure testing and adjustment are described in

Service Procedures, Loader Valve — Pressure

Testing

.

Weight

25kg (55lbs) (3 spool)

TBA (2 spool)

4

5

6

7

Component Key:

1 Arms lift service

2 Shovel service

Pump section 1 — inlet

Pump section 2 — inlet

Pressure test port

Unloader Assembly

8

9

10

11

12

13

14

Unloader solenoid

Auxiliary relief valve

Tank port

High pressure carry-over (HPCO) port

Service ports

Load hold check valve assemblies

Data plate

1

2 3

7

9

8

@

@

@

6

5

$

£

0

!

@

@

@

4

9

A262160

Issue 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 5

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 5

Relief Valve Pressures

Loader Valve — Precision Control (Servo)

*

(Machines up to serial no. 931159)

Main Relief Valve (M.R.V.)

Unloader Valve

Auxiliary Relief Valves (A.R.V.)

Loader

Shovel Ram Head Side

Shovel Ram Rod side

Bolt on Auxiliary Spool (extending dipper, if fitted)

Top relief valve

Bottom relief valve

bar

227 — 231

203 — 207

172 — 175

308 — 312

136 — 140

205 — 208

kgf/cm 2

232 — 235

207 — 211

175 — 179

315 — 318

139 — 142

209 — 212

lbf/in 2

3300 — 3350

2950 — 3000

2500 — 2550

4475 — 4525

1975 — 2025

2975 — 3025

Note:

Instructions for pressure testing and adjustment are described in

Service Procedures, Loader Valve — Pressure

Testing

.

Component Key:

1

2

Arms lift service

Shovel service

11

12

13

14

15

16

4

5

8

9

6

7

10

Pump section 1 — inlet

Pump section 2 — inlet

Pressure test port

Unloader Assembly

Unloader solenoid

Auxiliary relief valve

Tank port

High pressure carry-over (HPCO) port

Service ports

Load hold check valve assemblies

Main relief valve (MRV)

Bolt on auxiliary spool

Data plate

5

15

9

8

7

1

2

9

3

@

@

@

@

6

13

13 13

16

@

@

@

@

4

9

9

10

11

14

A402480

Issue 3*

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 5A

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 5A

Relief Valve Pressures

Loader Valve — Precision Control (Servo)

(Machines from January 2003)

Auxiliary Relief Valves (A.R.V.)

Shovel Ram Head Side

Shovel Ram Rod Side

bar

310

170

kgf/cm

315

175

2 lbf/in

4500

2500

2

Note:

Instructions for pressure testing and adjustment are described in

Service Procedures, Loader Valve — Pressure

Testing

.

Component Key:

2

5

6

3

4

7

8

9

Shovel service

Arms lift service

Auxiliary relief valves

Electric detent spool connector

Inlet port (secondary pump section P2)

Tank port

Inlet port (main pump section P1)

Service ports

7

8

T

P

1 2 3

A

9

4

A

9

A

9

9 9 9

B B B

4

T

LS

6

P

9803/3280

5

Purchased from www.WorkshopManuals.co.uk

A403690

Issue 1

Section E

2 — 7

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 7

Relief Valve Pressures

Loader Valve — Variable Flow

Priority Relief Valve†

Auxiliary Relief Valves (A.R.V.) @ 0.5gal/min (1.9 litres/min)

Shovel Ram Head Side

Shovel Ram Rod side

bar

170 — 176

170 — 174

306 — 314

kgf/cm 2

173 — 179

173 — 177

312 — 320

lbf/in 2

2450 — 2550

2465 — 2520

4450 — 4550

† Note:

Steer circuit pressure is controlled by a relief valve housed in the hydraulic steer unit (Refer to Section H

Steering

).

The priority relief valve housed in the loader valve must be set at 2500 lb/in

2

, this will ensure it does not interfere with the operation of the relief valve housed in the hydraulic steer unit.

Weight

:

2 Spool — TBA kg (TBA lbs)

3 Spool — TBA kg (TBA lbs)

9

10

11

12

13

6

7

4

5

8

2

3

Component Key:

1 Auxiliary (optional) service

Shovel service

Arms lift service

Pump inlet

Tank port

Load sense port (to pump)

Priority load sense port (from steer unit)

Priority work port (to steer unit)

Load sense carry over port (to backhoe valve)

Service ports

Auxiliary relief valve (rod side)

Auxiliary relief valve (head side)

Priority relief valve †

3 2 1

!

9

0 0

0

0

0

0

8

@

£

4

5

7

6

A273670

9803/3280

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 8

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 8

Relief Valve Pressures

Excavator Valve — Fixed Flow

Boom Ram Head Side

Boom Ram Rod Side

Bucket Ram Head Side

bar

248 — 255

345 — 352

Centremount (17′ , 15’ 6” backhoe — except knuckle) 310 — 317

Centremount (14′ backhoe, 15’ 6” backhoe with a knuckle fitted) 248 — 255

Sideshift

Bucket Ram Rod Side (Machines with Rockbreaker only)

Dipper Ram Head Side

248 — 255

248 — 255

248 — 255

Dipper Ram Rod Side

Slew Left and Right

248 — 255

262 — 269

kgf/cm 2

253 — 260

351 — 358

316 — 323

253 — 260

253 — 260

253 — 260

253 — 260

253 — 260

267 — 274

lbf/in 2

3600 — 3700

5000 — 5100

4500 — 4600

3600 — 3700

3600 — 3700

3600 — 3700

3600 — 3700

3600 — 3700

3800 — 3900

Weight:

44 kg (97 lbs) — Centremount

46 kg (101 lbs) — Sideshift

Note

: Instructions for pressure testing and adjustment are described in

Service Procedures, Loader Valve — Pressure

Testing

.

† System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the bottom ARV from spool 2.

4

5

2

3

6

Component Key:

1 Bucket crowd

7

Dipper †

Stabiliser

Stabiliser

Boom †

Slew

Auxiliary relief valve

8

9

10

11

12

13

14

Tank port

High pressure carry-over (HPCO) port

Service ports

Load hold check valve assemblies

Make-up check valve assembly

Inlet port

Hydraclamp solenoid

1 2 3 4 5 6

7

7 7

8

0

0

0 0

0 0

!

!

!

!

!

!

0 0

0

0

0

0

@

£

$

9

7 7

7 7

A401470

9803/3280

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 10

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 10

Relief Valve Pressures

Excavator Valve — Precision Control (Servo)

*

(Machines up to serial no. 931159)

Boom Ram Head Side

Boom Ram Rod Side

Bucket Ram Head Side

Bucket Ram Rod Side

Dipper Ram Head Side

Dipper Ram Rod Side

Slew Left and Right

Load Sense Relief Valve

† bar

248 — 255

345 — 352

248 — 255

248 — 255

248 — 255

248 — 255

262 — 269

208 — 212

kgf/cm

2

253 — 260

351 — 358

253 — 260

253 — 260

253 — 260

253 — 260

267 — 274

213 — 216

lbf/in

2

3600 — 3700

5000 — 5100

3600 — 3700

3600 — 3700

3600 — 3700

3600 — 3700

3800 — 3900

3025 — 3075

Note

: Instructions for pressure testing and adjustment are described in

Service Procedures, Loader Valve — Pressure

Testing

.

† Note:

For pressure testing and adjustment of the load sense relief valve, see

Service Procedures, Pressure Testing, Load

Sense Drain Regulator and Relief Valve

.

6

7

8

Component Key:

3

4

1

2

5

Bucket

Dipper

Stabiliser

Stabiliser

Boom

Slew

Auxiliary relief valve

Tank port

9

10

11

12

13

14

15

Pilot operated check valve (hydraclamp)

Service ports

Load sense valve

Load sense drain regulator and relief valve

Inlet port

Hydraclamp solenoid

Auxiliary spool

1 2 5

6

15

3

4

12

7

7

7 7

8

10 10

10 10 10 10 10

11 11 11

11

11 11 11

10 10 10 10 10 10 10

7 7 7

7

9

13

14

A402500

Issue 3*

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 10A

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 10A

Relief Valve Pressures

Excavator Valve — Precision Control (Servo)

(Machines from January 2003)

Auxiliary Relief Valves (A.R.V.)

Boom Ram Head Side

Boom Ram Rod Side

Bucket Ram Head Side

Bucket Ram Rod Side

Dipper Ram Head Side

Dipper Ram Rod Side

Slew Left and Right

bar

245

350

255

255

255

255

265

kgf/cm 2

250

355

260

260

260

260

270

lbf/in 2

3550

5000

3700

3700

3700

3700

3850

Load Sense Relief Valve

†

250 255 3650

Note

: Instructions for pressure testing and adjustment are described in

Service Procedures, Loader Valve — Pressure

Testing

.

† Note:

For pressure testing and adjustment of the load sense relief valve, see

Service Procedures, Pressure Testing, Load

Sense Relief Valve

.

Component Key:

6

7

8

3

4

1

2

5

Auxiliary (options)

Bucket

Dipper

Stabiliser

Stabiliser

Boom

Slew

Auxiliary relief valves

9

10

11

12

13

14

15

Anti-cavitation valve

Load sense relief valve

Flow regulator valve

Hydraclamp solenoid

Inlet port

Tank port

Service ports

10

11

14

M

13

T

P

1 2

3 4 5 6 7

10

12

C

T3

A

9

15

8

A A

8

15 15

A

15

A

15

8

A

15

8

A

15

15 15

B

8

8

B

15

8

B

15

B

15

B

15

B

8

15

B

8

T

M

T1

LS

P

A403680

9803/3280

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

2 — 11

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 11

Relief Valve Pressures

Auxiliary Valve — Fixed Flow

Extradig Ram Head Side

Extradig Ram Rod Side

Jaw Bucket Ram Head Side

Jaw Bucket Ram Rod Side

Knuckle Ram Head Side

Knuckle Ram Rod Side

Hammermaster

Power Sideshift (both)

Hand Held Tools

4

7

2

3

8

Component Key:

1 Auxiliary Spool

2 Inlet port

Outlet port

Auxiliary relief valve

High pressure carry-over (HPCO) port

Service ‘A’ ports

Service ‘B’ ports

Weight:

TBA kg (TBA lbs)

bar

138 — 145

207 — 214

138 — 145

207 — 214

138 — 145

207 — 214

207 — 214

207 — 214

138 — 150

kgf/cm 2

141 — 148

211 — 218

141 — 148

211 — 218

141 — 148

211 — 218

211 — 218

211 — 218

141 — 153

lbf/in 2

2000 — 2100

3000 — 3100

2000 — 2100

3000 — 3100

2000 — 2100

3000 — 3100

3000 — 3100

3000 — 3100

2000 — 2200

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

2 — 13

www.WorkshopManuals.co.uk

Hydraulics

Technical Data

Section E

2 — 13

Smooth Ride System

System Type

Charging Gas

Accumulator Capacity

Accumulator Weight

Accumulator Charge Pressure

As a general guide for given shovel weights (loaded) see below:-

A piston type accumulator operates as a liquid spring absorbing displaced fluid from the lift rams. Selectable from a switch in the cab.

Air Free Dry Nitrogen

1.0 litre (58 cu/in)

4.4 kg (9.75 lb)

Shovel weights up to 700 kg (1540 lb)

Shovel weights 700 kg to 950 kg (1540 — 2100 lb)

Shovel weights over 950 kg (2100 lb)

bar

13.8

19

24

kgf/cm

2

14

19.4

24.5

lbf/in

200

275

350

2

Note:

Replacement accumulators will only be supplied in an uncharged, non pressureised condition to meet Health and

Safety/Airfreight hazardous goods requirements.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Component Location www.WorkshopManuals.co.uk

3

7

1B

4

13

P

6

26

1C

T

A401400

Purchased from www.WorkshopManuals.co.uk

Component Location

Component Key:

T

Hydraulic Tank

P

Hydraulic Pump (engine driven)

1B

Hose — High Pressure Carry Over

3

Loader Valve Block

4

Excavator Valve

6

Return Line Filter (inside hydraulic tank)

7

Steer Circuit Priority Valve

13

Return Line Check Valve

26

Hydraulic Oil Cooler

www.WorkshopManuals.co.uk

Neutral Circuit Description

Fixed Flow — Single Pump

Oil is drawn from the hydraulic tank

T

by the single stage hydraulic pump

P

. The pump is mounted on the rear of the gearbox and is engine driven via a driveshaft.

Pressurised oil from the pump flows to steering priority valve

7

, and in neutral circuit flows through the priority valve to the loader valve

3

.

From the loader valve neutral gallery, oil flows via a high pressure carry-over line

1B

to the excavator valve

4

.

Some of the exhaust oil flows directly back to the tank through an in-tank filter

6

, and some of the exhaust oil returns to tank via the hydraulic oil cooler

26

.

To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve

13

fitted to t he ret urn line. The c hec k valve raises approximately 5 bar (75 lbf/in

2

) of pressure in the line, which improves the operation of the respective anti-cavitation valves.

Purchased from www.WorkshopManuals.co.uk

Component Location www.WorkshopManuals.co.uk

26

3

7

1B

4

5

13

62

5

P1

P2

6

1C

T

A401420

Purchased from www.WorkshopManuals.co.uk

Component Location

Component Key:

T

Hydraulic Tank

P1

Hydraulic Pump (main section)

P2

Hydraulic Pump (secondary section)

1B

Hose — High Pressure Carry Over

3

Loader Valve Block

4

Excavator Valve

5

Auxiliary Valve

6

Return Line Filter (inside hydraulic tank)

7

Steer Circuit Priority Valve

13

Return Line Check Valve

26

Hydraulic Oil Cooler

62

Hydraclamp exhaust hose

www.WorkshopManuals.co.uk

Neutral Circuit Description

Fixed Flow — Double Pump

Oil is d raw n from t he hyd raulic t ank

T

b y t he hydraulic pump. The pump has two sections,

P1

and

P2

.

The hydraulic pump is mounted on the rear of the g earb o x and is d riven b y t he eng ine via a driveshaft.

Oil from the larger section

P1

flows direct to the loader valve

3

. Oil from pump section

P2

, flows to steering priority valve

7

, and in neutral circuit flows through the priority valve to the auxiliary valve

5

and then to join the flow from

P1

at the loader valve.

From the loader valve neutral gallery, oil flows via a high pressure carry-over line

1B

to the excavator valve

4

.

Some of the exhaust oil flows directly back to the tank through an in-tank filter

6

, and some of the exhaust oil returns to tank via the hydraulic oil cooler

26

.

To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve

13

fitted to t he ret urn line. The c hec k valve raises approximately 5 bar (75 lbf/in

2

) of pressure in the line, which improves the operation of the respective anti-cavitation valves.

On sideshift machines only, hydraclamp exhaust ho se

62

is f it t ed . The ho se c o nnec t s t he hydraclamp spool directly into the exhaust circuit.

This prevents the clamps from ‘locking-up’ when the sideshifting operation is required.

Purchased from www.WorkshopManuals.co.uk

Component Location www.WorkshopManuals.co.uk

4

3

1A

5

13

P

26

6

T

A401430

Purchased from www.WorkshopManuals.co.uk

Component Location

Component Key:

T

Hydraulic Tank

P

Hydraulic Pump (engine driven)

1A

Pump Outlet Pipe/Hose

3

Loader Valve Block

4

Excavator Valve

6

Return Line Filter (inside hydraulic tank)

13

Return Line Check Valve

26

Hydraulic Oil Cooler

www.WorkshopManuals.co.uk

Neutral Circuit Description

Variable Flow

The variable flow displacement pump

P

is mounted on the rear of the gearbox and is engine driven via a driveshaft.

With variable flow hydraulics, there is no ‘neutral’ circuit. This is because the pump

P

operates on a d emand signal from t he servic es (see

Circuit

Descriptions, Hydraulic Pump — Variable Flow

Operation

). If there is no demand, then the pump d oes not d raw oil from t he t ank and no oil is delivered, there is no pump flow in the neutral position.

When a service is selected, the pump senses the demand and oil is drawn from the hydraulic tank

T

.

Pressurised oil from the pump flows to the loader valve

3

and/or the excavator valve

4

via hose and pipe assembly

1A

.

The loader valve

3

is fitted with a priority inlet manifold, oil entering the loader valve is distributed to the (priority) steer circuit and/ or the loader services as required (see

Circuit Descriptions,

Loader Valve — Variable Flow Operation

).

Some of the exhaust oil flows directly back to the tank through an in-tank filter

6

, and some of the exhaust oil returns to tank via the hydraulic oil cooler

26

.

To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve

13

fitted to t he ret urn line. The c hec k valve raises approximately 5 bar (75 lbf/in

2

) of pressure in the line, which improves the operation of the respective anti-cavitation valves.

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 10

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 10

Introduction to Hydraulic Schematic

Symbols

Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.

There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only variations or refinements on the basic principles explained here. If more detailed information is required you are recommended to obtain a copy of BS2917 or IS01219.

Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components.

General (Basic & Functional Symbols)

Spring

Pumps & Motors

Variable capacity pump two directions of flow

Fixed capacity motor one direction of flow

Fixed capacity motor two directions of flow

Variable capacity motor one direction of flow

Flow restriction affected by viscosity

Direction of flow

Indication of rotation

Variable capacity motor two directions of flow

Indication of direction and paths of flow

Variable control

A189660

Rams

Single acting

Double acting

Double ended

Double acting with damping at rod area end

A189670

A189680

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 11

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 11

Introduction to Hydraulic Schematic

Symbols (cont’d)

Control Valves

One way restrictor

Used to enclose several valves indicating that they are supplied as one unit

9803/3280

3-Position, 4-Port spring centred pilot operated valve

High pressure selector

(shuttle valve)

3-Position, 6-Port spring centred hand operated valve

Throttling orifice normally closed

3-Position, 4-Port spring centred solenoid & pilot pressure operated valve

3-Position, 4-Port spring centred detent hand operated valve

Non — return valve

Throttling orifice normally open

Relief valve

Non — return valve with back pressure spring

Pilot operated non — return valve

A189690

Purchased from www.WorkshopManuals.co.uk

Variable restrictor

A189700

Issue 1

Section E

3 — 12

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 12

Introduction to Hydraulic Schematic

Symbols (cont’d)

Energy Transmissions and Conditioning

Working line, return or feed

Reservoir — return line above fluid level

Pilot control

Reservoir — return line below fluid level

Drain lines

Flexible pipe

Header tank

Pressure sealed tank

Line junction

9803/3280

Accumulator

Crossing lines

Filter or strainer

Air bleed

Water trap

Line plugged, also pressure test point

Line plugged with take off line

Cooler — with no indication of coolant flow

Cooler — indicating direction of coolant flow

Quick release couplings — connected

A189710

Quick release couplings — disconnected

Heater

Purchased from www.WorkshopManuals.co.uk

A189720

Issue 1

Section E

3 — 13

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 13

Introduction to Hydraulic Schematic

Symbols (cont’d)

Control Mechanisms

Rotating shaft-one direction

Solenoid one winding

Rotating shaft-two directions

Solenoid two winding

Detent

M Electric motor operated

Locking device

Internal pressure pilot operated

Over centre device

External pressure pilot operated

Simple linkage

Pressure operated spring release

General control

Pilot operated by solenoid pilot valve

Push button operated

Pilot operated by a solenoid or separate pilot valve

Lever operated

Pressure gauge

Pedal operated

Stem operated

Pressure switch

Spring operated

Roller operated

Roller trip operated

(one directional)

S189730

S189740

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 14

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 14

Introduction to Hydraulic Schematic

Symbols (cont’d)

Control Valves

Control valves are usually represented by one or more square boxes.

Fig. 1 shows a control valve represented by three boxes.

The number of boxes indicates the number of possible valve operating positions, (4 boxes — 4 positions etc).

Fig. 2 — In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).

Fig. 3 shows a valve described as a 3- position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position 2 indicates that in an unoperated condition all 4 ports are blocked.

If the valve spool was moved to Position 1, movement of the spool would connect Port 1 to Port 2, and Port 3 to Port 4.

If the valve spool was moved to Position 3, movement of the spool would connect Port 1 to Port 4, and Port 3 to Port 2.

It must be noted that not all spools are of the same type.

Their operating designs can be seen by following the path the flow arrows take in their respective operating squares.

Three typical JCB style spools are known as ‘D’ spools, ‘F’ spools and ‘N’ spools.

The ‘D’ spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. Fig 3 shows a ‘D’ type spool.

Fig 4 — ‘F’ spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to ‘float’.

Fig 5 — ‘N’ spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port

FIG 4

FIG 5

Position 1 Position 2 Position 3

FIG 2

FIG 3

Port 1

Port 2

Port 3

Port 4

9803/3280

Purchased from www.WorkshopManuals.co.uk

A189760

Issue 1

Section E

3 — 15

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 15

Introduction to Hydraulic Schematic

Symbols (cont’d)

Example of Schematic Circuit

Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit shown below.

Hydraulic tank

A

is a pressurised tank with an internally mounted strainer

B

on the suction line to the fixed displacement pump

C

. System pressure is limited to the setting of relief valve

D

.

Valve spool

E

is an open-centre spool that is in neutral position; flow from the pump passes through the spool and returns to the hydraulic tank.

If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram

G

. Notice that the fluid must first open one way valve

F

before flowing to the ram.

A

B

C

D

E

F

G

Example Circuit Key

Hydraulic Tank

Strainer

Fixed Displacement Pump

Relief Valve

Spool

One Way Valve

Double Acting Hydraulic Ram

A

B

C

D

F

E

G

9803/3280

Purchased from www.WorkshopManuals.co.uk

A189770

Issue 1

Section E

3 — 20

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Fixed Flow

Section E

3 — 20

3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines

The policy of JCB is one of continuous improvement, therefore as products develop, there may be variations to the circuits.

4P

5

5A

5B

5C

4J

4K

4L

4M

4N

4B

4C

4D

4E

4F

4G

4H

9

10

11

12

13

6

6A

6B

7

8

3A

3B

3C

3D

3E

MM

1A

1B

2A

3

Component Key

C Tank Cap

JJ

P1

Connections (as applicable)

Pump, Main Section

P2

P2A

S

T

M

Pump, Secondary Section

Pressure Test Point (auxiliary & unloader)

Suction Line

Tank

Connections (as applicable)

Quick Release Couplings

Neutral Circuit Line

Neutral Circuit Line

Neutral Circuit Line

Loader Valve Block

Pressure Test Point (M.R.V.)

Unloader Pilot Valve

Loader Lift Ram Spool

Loader Shovel Ram Spool

Clamshovel Spool

3F

3G

3J

3L

3M

Shovel Ram Head Side A.R.V.

Shovel Ram Rod Side A.R.V.

Load Hold Check Valve

Unloader Valve Spool

Main Relief Valve

3N

3Q

Unloader Check Valve

Hydraulic Speed Control Solenoid

4 Excavator Valve Block

Excavator services shown here are to the JCB control pattern. If ISO, Case or Ford control pattern is used, the excavator spools and relief valves will apply to different services.

Boom Spool

Stabiliser Spool

Stabiliser Spool

Dipper Spool

Bucket Spool

Hydraclamp Valve (Sideshift Machines Only)

Slew A.R.V.

Slew A.R.V.

Boom Ram Rod Side A.R.V.

Boom Ram Head Side A.R.V.

Dipper Ram Head Side A.R.V.

Dipper Ram Rod Side A.R.V.

Bucket Ram Head Side A.R.V.

Auxiliary Valve Block (foot operated)

Auxiliary Spool

A.R.V.

A.R.V.

In-tank Filter

Filter By-pass Valve

Suction Strainer

Priority Valve

Filter

Filter

Diverter Valve (hammer only)

Sequence Valve (hammer only)

Flow Regulator Valve

Anti-cavitation Check Valve

9803/3280

59

62

65

66

67

53

54

55

56

57

68

69

70

71

42

43

44

51

52

36

38

39

40

41

31

32

33

34

35

14

15

16

26

JJ

M

M

Check Valve (optional)

Smooth Ride System Selector Valve Assembly

Smooth Ride System Accumulator

Hydraulic Oil Cooler

Shovel Ram R.H.

Shovel Ram L.H.

Lift Ram R.H.

Lift Ram L.H.

Clam Shovel Ram R.H.

Clam Shovel Ram L.H.

2 Wheel Steer Power Track Rod

AWS Rear Axle Power Track Rod

AWS Front Axle Power Track Rod

AWS Valve Assembly

Steer Control Valve

Shock Valves

Steer Control Valve Relief Valve

Bucket Ram

Boom Ram

Stabiliser Ram

Stabiliser Ram

Dipper Ram

Left Hand Slew Ram

Right Hand Slew Ram

Stabiliser Check Valve

Hydraclamps (Sideshift Machines Only)

Restrictor

Dipper Restrictor with By-Pass

Manual Isolation Valve

Manual Change Over Valve

Extending Dipper Ram

High Flow Options

Low Flow options

70

HIGH FLOW OPTIONS

71

LOW FLOW OPTIONS

Hammer

69

67

68

11

EXTENDING

DIPPER

MM

Purchased from www.WorkshopManuals.co.uk

MM

MM

A325660

Issue 1

Section E

3 — 21

Hydraulics www.WorkshopManuals.co.uk

Circuit Schematics — Fixed Flow

3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines

Section E

3 — 21

C

6

6A

T

S

6B

31

33

35

P2 P1

26

2A

34

P1

T

16

P2

15

ACC

13

32

1A

36

1B

62

3

3E

3F

3D

3J 3G

3B

3Q

3M

3L

3N

3C

3J

8

3A

40

39

44

43

41

7

42

P2A

9

12

38

14

4C

4D

4E

4F

4A

4B

4

4H

4J

4K

4L

4G

4M

4N

4P

T

54

59

59

66

53

10

11

65

56

57

55

52

JJ

JJ

51

5A

5B

5C

M

M

A262643

Issue 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 22

9808/3280

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Fixed Flow

3CX ‘S’ Series & 4CX Gear Pump Options

This c irc uit sho w s t he Ex t end ing Dip p er and Po w er

Sideshift, for the main hydraulic circuit see pages E/3-20 and E/3-21.

Component Key

72

73

74

75

76

HPCO High Pressure Carry Over (From Excavator Valve

Block 4)

M Hydraulic Connections

MM

T

10

11

69

Quick Release Couplings

Hydraulic Tank Return

Diverter valve

Sequence valve

Extending Dipper Ram

Change Over Valve

Power Sideshift Cylinder

Relief Valve

Manual Change Over Valve

Isolation Valve

Section E

3 — 22

3CX ‘S’ Series Options

This circuit shows the Low Flow Hammer, Extending Dipper and Power Sideshift, for the main hydraulic circuit see pages E/3-20 and E/3-21.

Component Key

69

72

73

74

76

77

HPCO High Pressure Carry Over (From Excavator Valve

M

MM

T

11

Block 4)

Hydraulic Connections

Quick Release Couplings

Hydraulic Tank Return

Sequence valve

Extending Dipper Ram

Change Over Valve

Power Sideshift Cylinder

Relief Valve

Isolation Valve

Hammer

69

69

11

HPCO

M

10

72

75

77

76

74

T

73

A325670

M

M

72

HPCO

11

73

76

74

T

A327030

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 23

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Fixed Flow

Section E

3 — 23

3CX ‘S’ Series Options

This circuit shows the Low Flow Hammer and Extending

Dipper, for the main hydraulic circuit see pages E/3-20 and

E/3-21.

Component Key

HPCO High Pressure Carry Over (From Excavator Valve

Block 4)

M

T

11

Hydraulic Connections

Hydraulic Tank Return

Sequence valve

69

76

77

Extending Dipper Ram

Isolation Valve

Hammer

69

77

11

HPCO

76

T

M

M

A327040

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

3 — 24

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Fixed Flow

Section E

3 — 24

214e Machines

Component Key:

Z

AA

BB

CC

DD

S4

S5

S6

W

Y

EE

FF

GG

HH

1

N

P

Q

S

S1

S2

S3

J1

J2

J3

J4

K

L

M

E

F

G

H

J

A

B

C

D

Hydraulic Tank

Return filter

Hydraulic Oil Cooler

Hydraulic Pump

Twin Check Valve

Shovel Rams

Quick Release Couplings

Lift Rams

Loader Valve Block

Main Relief Valve

Auxiliary Spool

Lift Spool

Shovel Spool

Flow Regulator Valve (Option)

Pressure Test Point

Auxiliary Valve Block (Option)

Either option K or M can be fitted but not both.

Steer Control Valve

Auxiliary Rams

Priority Valve

Excavator Valve Block

Slew Spool

Boom Spool

Stabiliser Spool

Stabiliser Spool

Dipper Spool

Bucket Spool

Stabiliser Rams

One Way Restrictor

Slew Rams

Boom Ram

Dipper Ram

Bucket Ram

Suction Strainer

Stabiliser Check Valve

Last Chance Filter

Tank Cap

Extending Dipper

2WS Front Power Track Rod

Note

: For smooth ride system schematic, refer to

Circuit

Descriptions — Smooth Ride System

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

3 — 25

214e Machines

GG

B

A

DD

F

H

P

D

ENGINE

9803/3280

C www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Fixed Flow

Section E

3 — 25

E

H

F

P

NEUTRAL CIRCUIT H.P.C.O.

S1

FF

S

EE

W

SLEW

SHOVEL

J4

1

S2

LOADER

J3

MRV

J1

AUX

J2

L R

S3

N

S4

S5

J

P LS T

EF

LS

P

Q

CF

PP

S6

BOOM

STABILISER

STABILISER

DIPPER

Z

Z

AA

Y

BB CC HH

L

NEUTRAL CIRCUIT / TANK RETURN

FF

K

BUCKET

H.P.C.O.

EE

W

HAMMERMASTER

260L

HAMMERMASTER

280

HAMMERMASTER

360

M

B

A

HAMMER RETURN

HAMMER FEED

G G

A408750

A408750

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 26

4CXE, 4CX Super Machines

(7 Spool With High Flow Options) www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Variable Flow

L

L1

20

20

S

3

21

4

21

2

22

1

T

22

7

P

B

P

5 6

8

T

L

P

48

R

45

46

T

47

LS

T

P

43

T

P1

24

ACC

23

P2

44

PR

10

P PRLS

17

LS

11

T

9

12

19

18

17

B

A

B

A

13

19

18

17

15

14

19

18

15

17

B

A

LS

B

A

T LS

17

26

15

18

15A

17

28

18

16

16

17

28

18

15

17

15

18

27

29

30

31

17

18

32

17

15

18

17

16

16

18

16A

33

34

25

P

B

A

B

A

B

A

B

A

B

A

B

A

B

A

51

50

54

49

49

36

38

39

52

53

37

40

41

Section E

3 — 26

A278942

Issue 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 27

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Variable Flow

Section E

3 — 27

4CX, 4CX Super Machines

(7 Spool With High Flow Options)

Component Key

Small letters on the schematic indicate port markings. Refer to Technical Data pages at the beginning of this section for more information. Ports

A

and

B

are always identified as service ports (feed and return from respective ram).

6

7

4

5

8

T

1

2

P

3

Hydraulic Tank

By-pass Filter

Suction Line

Pump Variable Flow

Stroking Piston

Control Piston

System Pressure Spool

Stand-by Pressure Spool

Hydraclamp Valve

Hydraclamps

9 Loader Valve Block

10 Priority Inlet Section

11 Relief Valve †

12 Auxiliary Service Spool

13 Shovel Service Spool

14 Lift Service Spool

15 Auxiliary Relief Valves (anti-cavitation)

15A ARV item 16 if Rockerbreaker Application

16 Auxiliary Relief Valves (direct acting)

16A ARV Only Fitted For Rockbreaker Application

17 Secondary Shuttle Valve

18 Primary Shuttle Valve

19 Load Hold Check Valve

20 Auxiliary Rams

21 Shovel Rams

22 Lift Rams

23 Smooth Ride Selector Valve

24 Smooth Ride Accumulator

25 Backhoe Loader Valve Block

26 Extradig Priority Valve

27 Extradig Service Spool

28 Compensator Valves

29 Slew Service Spool

30 Boom Service Spool

31 Stabiliser Service Spool

32 Stabiliser Service Spool

33 Dipper Service Spool

34 Bucket Service Spool

35 Extradig Ram

36 Slew Rams

37 Boom Ram

38 Stabiliser Ram

39 Stabiliser Ram

40 Dipper Ram

41 Bucket Ram

42 Accumulator

43 Oil Cooler

44 Load Sense Relief Valve

45 Steer Unit Assembly

46 Steer Valve

47 Relief Valve

48 Shock Valves

49 Quick release Couplings

50 Isolation Valve

51 Extending Dipper Isolation Valve

52 Foot Valve

53 Extending Dipper Ram

54 Hammer

† Note:

Steer circuit pressure is controlled by a relief valve housed in the hydraulic steer unit (refer to Section H

Steering

). The priority relief valve housed in the loader valve must be set at 2500 lb/in

2

(173 bar, 176 kgf/cm

2

) this will ensure it does not interfere with the operation of the relief valve housed in the hydraulic steer unit.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

3 — 28

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Variable Flow

Section E

3 — 28

4CX, 4CX Super Machines

(6 Spool With High/Low Flow Options)

Component Key

Small letters on the schematic indicate port markings. Refer to Technical Data pages at the beginning of this section for more information. Ports

A

and

B

are always identified as service ports (feed and return from respective ram).

6

7

4

5

8

T

1

2

P

3

Hydraulic Tank

By-pass Filter

Suction Line

Pump Variable Flow

Stroking Piston

Control Piston

System Pressure Spool

Stand-by Pressure Spool

Hydraclamp Valve

Hydraclamps

9 Loader Valve Block

10 Priority Inlet Section

11 Relief Valve †

12 Auxiliary Service Spool

13 Shovel Service Spool

14 Lift Service Spool

15 Auxiliary Relief Valves (anti-cavitation)

16 Auxiliary Relief Valves (direct acting)

16A ARV Only Fitted For Rockbreaker Application

17 Secondary Shuttle Valve

18 Primary Shuttle Valve

19 Load Hold Check Valve

20 Auxiliary Rams

21 Shovel Rams

22 Lift Rams

23 Smooth Ride Selector Valve

24 Smooth Ride Accumulator

25 Backhoe Loader Valve Block

28 Compensator Valves

29 Slew Service Spool

30 Boom Service Spool

31 Stabiliser Service Spool

32 Stabiliser Service Spool

33 Dipper Service Spool

34 Bucket Service Spool

36 Slew Rams

37 Boom Ram

38 Stabiliser Ram

39 Stabiliser Ram

40 Dipper Ram

41 Bucket Ram

42 Accumulator

43 Oil Cooler

44 Load Sense Relief Valve

45 Steer Unit Assembly

46 Steer Valve

47 Relief Valve

48 Shock Valves

49 Quick release Couplings

50 Isolation Valve

54 Hammer

55 Load Sense Isolation Valve

† Note:

Steer circuit pressure is controlled by a relief valve housed in the hydraulic steer unit (refer to Section H

Steering

). The priority relief valve housed in the loader valve must be set at 2500 lb/in

2

(173 bar, 176 kgf/cm

2

) this will ensure it does not interfere with the operation of the relief valve housed in the hydraulic steer unit.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

3 — 29

4CXE, 4CX Super Machines

(6 Spool With High Flow Options)

7

P

3

P

B

S

5 6

4

L

L1

20

20

A347590

9803/3280

21

2

22

T

1

21

22 www.WorkshopManuals.co.uk

8

T

X

L

P

48

R

45

46

T

47

LS

T

P

B

A

43

10

P PRLS

17

LS

11

T

9

PR

T

P1

24

ACC

23

P2

44

12

19

18

17

B

A

B

A

13

19

18

17

15

14

19

15

18

17

B

A

LS

Purchased from www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Variable Flow

55

50

54

49

49

Section E

3 — 29

T LS

17

28

18

16

16

17

28

18

15

17

15

18

29

30

31

17

18

32

17

15

18

17

16

16

18

16A

33

34

P

25

B

A

B

A

B

A

B

A

B

A

B

A

36

38

39

37

40

41

A327070

Issue 1

Section E

3 — 30

www.WorkshopManuals.co.uk

Hydraulics

Circuit Schematics — Variable Flow

Section E

3 — 30

4CX, 4CX Super Machines

Hand Held Tools Option

X

1

3

2

LS

4

T

9

LS

25

LS

P

5

6

A322650

Component Key

P

T

2

3

X

1

4

Pump Variable Flow

Hydraulic Tank

Main Circuit Connection

Pressure Flow Regulator

High Pressure Flow Spool

Relief Valve (2000 lb/in 2

Load Sense Solenoid

— 138 bar — 146 kgf/cm 2 )

5

6

Hand Held Tool

Shuttle Valve

9 Excavator Valve Block

25 Loader Valve Block

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

3 — 31

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 31

Hydraulic Circuit Schematic

Precision Control (Servo)

*

(Machines up to serial no. 931159)

Component Key:

4Q

4R

4S

4T

4U

4K

4L

4M

4N

4P

4B

4C

4D

4E

4F

4G

4H

4J

3L

3M

3N

3P

3Q

3D

3E

3F

3G

3H

4

2A

3

3A

3B

3C

1

1A

1B

1C

2

Tank

Breather

Fill Screen

Suction Strainer

Pump, Main Section

Pump, Secondary Section

Loader Valve Block

Extending Dipper Spool

Loader Lift Ram Spool

Loader Shovel Ram Spool

Clamshovel Spool

Extending Dipper Ram Rod Side A.R.V.

Extending Dipper Ram Head Side A.R.V.

Shovel Ram Head Side A.R.V.

Shovel Ram Rod Side A.R.V.

Unloader Valve Spool

Main Relief Valve (MRV)

Unloader Check Valve

Unloader Pilot Valve

Hydraulic Speed Control Solenoid

Excavator Valve Block

Boom Spool

Right Stabiliser Spool

Left Stabiliser Spool

Dipper Spool

Bucket Spool

Auxiliary Spool

Hydraclamp Valve (Sideshift Only)

Slew A.R.V.

Slew A.R.V.

Dipper Ram Head Side A.R.V.

DipperRam Rod Side A.R.V.

Boom Ram Rod Side A.R.V.

Boom Ram Head Side A.R.V.

Bucket Rod Side ARV (Hammer Only)

Bucket Ram Head Side A.R.V.

Bypass Compensator Valve

Load Sense Drain Regulator and Relief Valve

Pilot Operated Check Valve (Hydraclamp)

18

19

20

21

22

23

24

10

11

12

13

14

7

8

5

6

9

15

16

Anti Cavitation Check Valve

Hydraulic Oil Cooler

Steer Unit

Priority Valve

2WS Power Track Rod Ram

Extending Dipper Ram

Lift Ram L.H.

Lift Ram R.H.

Shovel Ram L.H.

Shovel Ram R.H.

Clam Shovel Ram L.H.

Clam Shovel Ram R.H.

Dipper Ram

Stabiliser Ram

Stabiliser Ram

Boom Ram

Slew Ram L.H.

Slew Ram R.H.

Hydraclamps (Sideshift Only)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

3 — 32

Precision Control (Servo)

*

(Machines up to serial no. 931159)

4

4R

17

4Q 4P www.WorkshopManuals.co.uk

23

Hydraulics

Circuit Schematics

24

18

19 20 21

22

4N

4M 4L 4K 4J

4U

4H

Section E

3 — 32

1

1A

5

4G

4F

6

4E

1B

1C

2A

2

4D 4C 4B 4A

4T

4S

8

7

9

11 12

13 14 15 16

3E 3F

10

3A

3M

3Q

3N

3L

3P

3B

3G

3C

3H

3D

3

9803/3280

Purchased from www.WorkshopManuals.co.uk

A396210

Issue 2*

www.WorkshopManuals.co.uk

Section E

3 — 33

Precision Control (Servo)

(Machines from January 2003)

Hydraulics

Circuit Schematics

Section E

3 — 33

1

1B

1C

5

2A 2

9

11

7

9803/3280

6

8

10

12

3

A3

B3 b

A2

B2 b

A1

B1 b a

3C

3E

a

3B

3D

a

3A

P2

P

LS

14

13

15

T2

T

C

17

TP

P

T

18

16

T2

T1 a

4J

T

4V

4U

LS P

P2

M

4W

4A

b

B1

A1 a

4K

4L

4B

b

B2

A2

4M

a

4C

b

B3

A3 a a a

4N

4P

4Q

4D

b

B4

A4

4E

b

B5

A5

4F

b

B6

A6 a

4R

4S

4G

b

B7

A7

4T

4H

C

T3

4

19

23

24

25

22

26

21

20

HP

LP

P

HAMMER

(OPTION)

40

POWER SIDESHIFT

(OPTION)

45

HAMMER

(OPTION)

41

44

27

HAMMER

(OPTION)

42

43

A403921

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

3 — 34

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 34

Hydraulic Circuit Schematic

Precision Control (Servo)

(Machines from January 2003)

The schematic shows the main system hydraulics for

Precision Control (Servo) machines. For the pilot circuit refer to relevant pages.

Note:

The boom and dipper services are interchanged for the ISO control pattern.

Component Key:

4R

4S

4T

4U

4V

4L

4M

4N

4P

4Q

4W

4F

4G

4H

4J

4K

4B

4C

4D

4E

1

1B

1C

2

2A

3

3A

3B

3C

3D

3E

4

Small letters on the schematic indicate port markings. Refer to

Technical Data

pages at the begining of this section for more information. Ports

A

and

B

are always identified as service ports (feed and return from respective ram).

Tank

Return Filter

Suction Strainer

Pump, Main Section

Pump, Secondary Section

Loader Valve Block

Loader Lift Ram Spool

Loader Shovel Ram Spool

Clam Shovel Spool

Shovel Ram Head Side A.R.V.

Shovel Ram Rod Side A.R.V.

Excavator Valve Block

Boom Spool (Dipper ISO)

Right Stabiliser Spool

Left Stabiliser Spool

Dipper Spool (Boom ISO)

Bucket Spool

Extending Dipper Spool

Hydraclamp Valve (Sideshift Only)

Slew A.R.V.

Slew A.R.V.

Boom Ram Rod Side A.R.V.

Boom Ram Head Side A.R.V.

Dipper Ram Head Side A.R.V.

Boom Ram Rod Side A.R.V.

Bucket Ram Head Side A.R.V. (Hammer Only)

Bucket Ram Rod Side A.R.V.

Extending Dipper Ram Rod Side A.R.V.

Extending Dipper Ram Head Side A.R.V.

Flow Regulator Valve

Flushing Valve

Load Sense Relief Valve

17

18

19

20

21

12

13

14

15

16

5

6

7

8

9

10

11

22

23

24

25

26

27

Hydraulic Oil Cooler

Anti Cavitation Check Valve

Lift Ram R.H.

Lift Ram L.H.

Shovel Ram R.H.

Shovel Ram L.H.

Clam Shovel Ram R.H.

Clam Shovel Ram L.H.

Steer Mode Control Valve

Steer Unit

AWS Power Track Rod Rams

2WS Power Track Rod Ram

Unloader Valve

Priority Valve

Stabiliser Ram R.H.

Stabiliser Ram L.H.

Hydraclamps (Sideshift Only)

Boom Ram (Dipper ISO)

Slew Ram R.H.

Slew Ram L.H.

Dipper Ram (Boom ISO)

Bucket Ram

Extending Dipper Ram

Hammer Option:

40

41

42

43

Hammer Flow Valve

Hammer Selector Valve

Hammer Feed Coupling QR

Hammer Return Coupling QR

Power Sideshift Option:

44 Power Sideshift Selector Valve

45 Power Sideshift Ram

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

3 — 35

www.WorkshopManuals.co.uk

Hydraulics

Basic System Operation

Section E

3 — 35

Hydraulic Circuit Schematic

Precision Control (Servo)

(Machines from January 2003)

The schematic shows the pilot circuit for Precision Control

(Servo) machines. For the main system hydraulics refer to relevant pages.

Note:

The boom and dipper services are interchanged for the ISO control pattern.

Component Key:

32

33

34

35

25

26

27

30

31

4

19

20

21

22

23

24

Small letters on the schematic indicate port markings. Refer to

Technical Data

pages at the begining of this section for more information. Ports

A

and

B

are always identified as service ports (feed and return from respective ram).

Excavator Valve Block

Stabiliser Ram R.H.

Stabiliser Ram L.H.

Hydraclamps (Sideshift Only)

Boom Ram (Dipper ISO)

Slew Ram R.H.

Slew Ram L.H.

Dipper Ram (Boom ISO)

Bucket Ram

Extending Dipper Ram

Joystick Controller L.H.

Servo Pressure Supply Valve

Joystick Controller R.H.

Stabiliser Control R.H.

Stabiliser Control L.H.

Footpedal Control (Extending Dipper)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

3 — 36

Precision Control (Servo)

(Machines from January 2003)

Hydraulics

Circuit Schematics

www.WorkshopManuals.co.uk

P1

31

T

30

1

P T

2

3 4

T P T P

1

33

2 1

34

2

T2

T1 a

T a

32

P2

PV

P T a a a a a

1 2 3 4

T P

1

35

2

4

T3

LS P

P2

M b

B1

A1 b

B2

A2 b

B3

A3 b

B4

A4 b

B6

A6 b

B7

A7

C b

B5

A5

9803/3280

Purchased from www.WorkshopManuals.co.uk

19

22

23

24

25

26

21

20

27

A405700

Section E

3 — 36

Issue 1

Section E

5 — 1

Component Key:

A

Spur Gear — Idler

B

Spur Gear — Driven

C

Channel

D

Recess

P1

Main Section

P2

Secondry Section

Section E

5 — 1 Circuit Descriptions

Hydraulic Pump — Fixed Flow

Single Pump — Operation

The hydraulic pump is a gear type. The basic principle of the pump depends on the meshing of the two spur gears

A

and

B

, one of which is engine-driven whilst the other is an idler.

Oil is picked up on the inlet side of the pump by the gears and carried round between the gear teeth and the pump body. As the gears come into mesh the oil is forced through the pump outlet port.

Lubrication is provided by the hydraulic oil which is directed around the unit, via special oil ways, by the motion of the meshing gears.

9803/3280

Double Pump — Operation

Both sections

P1

and

P2

operate as described below:

The basic principle of the gear pump depends on the meshing of two spur gears

A

, one of which is engine driven while the other is an idler.

Oil is picked up by the gear teeth on the inlet side of the pump and carried around betwwen the teeth and the pump body. As the gears come into mesh, the space carrying the oil is filled by a gear tooth on the mating gear, forcing the oil out of the space and the through the pump outlet.

The wear plates

B

are loaded towards the gears by pressurised oil which is fed to the backs of the wear plates via channels

C

. This ensures that the clearance between the wear plates and gears is prevented from becoming excessive as outlet pressure rises.

The side of each wear plate that faces the gears has two recesses

D

. The recess on the inlet side of the pump assists the flow of oil into the gear spaces, thus raising the cavitation threshold of the pump. The recess on the outlet side vents oil trapped between meshing gear teeth to prevent compression loads on the bearings.

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

5 — 2

Circuit Descriptions

B

Section E

5 — 2

A

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

A

9803/3280

A

B

P1

D

C

P2

Purchased from www.WorkshopManuals.co.uk

A396380

Issue 1

Section E

5 — 3

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 3

Hydraulic Pump — Variable Flow

Operation

The pump is a variable displacement axial piston type.

Displacement of oil is achieved by the continuous operation of nine pistons. Pump fluid output is controlled by a tilting cam (swashplate), the angle of which is regulated to ensure that only the amount of fluid necessary to satisfy load conditions is delivered. If a load condition is such that no flow is req uired , only suffic ient fluid for c ooling and lubrication is provided.

Main components of pump

P

are a cylinder barrel

1

splined to a drive shaft

2

which is held against a kidney plate

3

.

Contained in the cylinder barrel are the axial pistons

4

, each having an articulated shoe that is in held contact with the swashplate

5

by an attachment plate

6

. The tilting action of the swashplate is exercised by a stroking piston

7

and a control piston

8

, the latter fed by servo pressure. Fitted to t he p um p ex t erio r is t he valve b lo c k

9

ho using t he pressure/flow regulators that provide servo control.

Rotation of the cylinder barrel causes linear movement of the axial pistons and fluid from the suction port is drawn into the pump through the kidney plate to fill a developing vacuum behind the piston. As the cylinder barrel rotates the fluid is carried from an elongated suction kidney to an elongated pressure kidney where linear movement starts to return the piston into the cylinder barrel. Fluid is forced from the pump through the pressure port.

The stroke length of the pistons and consequently the output of fluid is directly related to the swashplate angle. The swashplate is normally held in its maximum displacement angle by the stroking piston spring and system pressure inside the stroking piston.

Component Key:

P

3

4

1

2

5

8

9

6

7

Pump

Cylinder Barrel

Drive Shaft

Kidney Plate

Axial Piston

Swashplate

Shoe Plate

Stroking Piston

Control Piston

Pressure/Flow Compensator Valve

7 1 3

5

9803/3280

2

6

4

Purchased from www.WorkshopManuals.co.uk

8

S271440

Issue 1

Section E

5 — 4

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 4

Neutral Circuit Pressure

Pressure Generated by

Operation of a Service

Trapped Oil

Exhaust

13

9803/3280

P LS

2

1

11

6

4

10

T

A

9

P

5

12

3

8 7

Purchased from www.WorkshopManuals.co.uk

A275730

Issue 1

Section E

5 — 5

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 5

Hydraulic Pump — Variable Flow

Pressure/Flow Regulator Valve

The pressure and flow regulator valve assembly is mounted to the pump. The valve maintains the pump pressure and flow rate in accordance with demand at the service valve blocks.

Load Sensing — Stand-by Position

Stand-by is when the machine is running but the control levers are in neutral position, i.e. no implements are being used. There is no pressure or flow demands on the pump, therefore there will be no pressure signal .

With the engine switched off, spring

1

holds swashplate

2

at the maximum angle. When the engine is started and the pump begins to turn, oil begins to flow and pressure builds in the closed centre hydraulic system.

Valve

5

houses a flow regulator spool

4

and pressure regulator spool

3

. Pressure which is building in the closed centre system is sensed at port

P

of the regulator valve. The increasing pressure pushes flow compensating spool

4

up against its spring

6

. This movement creates a flow path from port

P

to port

A

. Oil now flows from the flow regulator valve

(via port

A

) to swashplate control piston

7

.

The control piston now moves the swashplate

2

towards its minimum angle. As the piston moves towards its full travel position, cross-drilled holes

8

are uncovered allowing oil to drain.

The cross-drilled holes limit the travel of the control piston when the holes are exposed, pump flow is insufficient to make up for leakage through the holes and maintain the pressure behind the control piston. Therefore the piston m o ves b ac k t o p art ially c o ver t he c ro ss ho les t hus maintaining enough flow to cater for normal system leakage w hilst est ab lishing a syst em st and — b y p ressure (see

Technical Data

for pressure).

3

5

4

A275760

1

P A

2

7

T

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

5 — 6

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 6

Neutral Circuit Pressure

Pressure Generated by

Operation of a Service

Trapped Oil

Exhaust

13

9803/3280

P LS

2

1

8 7

11

6

4

3

10

T

A

9

P

5

12

A275740

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

5 — 7

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 7

Hydraulic Pump — Variable Flow

Pressure/Flow Regulator Valve

Load Sensing — Maximum Flow

When a service is operated, the signal pressure from the loader (or backhoe) valve

13

increases. The increase in signal pressure combined with the force of spring

6

moves spool

4

down. Oil in control piston

7

is allowed to drain back to the tank via restrictor

9

and passage

10

.

The force of spring

1

is now sufficient to increase the angle of swashplate

2

. The increased angle of the swashplate increase the output of the pump.

The p ump out p ut p ressure w ill c ont inue t o inc rease, eventually the pressure will move flow regulating spool

4

against the force of spring

6

and the signal pressure in cavity

11

. Pump output pressure is now sent to control piston

7

via port

A

. Control piston

7

will overcome the force of spring

1

.

The pump swashplate angle decreases and therefore the pump outlet decreases. Eventually the pressure in the load sense line and the force of spring

6

will move spool

4

down and the ‘metering’ cycle starts again.

The up and down movement of the spool

4

keeps the pressure on both ends of the spool equal. Spring

6

is eq uivalent t o 20 b ar (290 lb f/ in

2

), t herefore t he p ump pressure should be this amount greater than the signal pressure (except when at maximum pressure — see

Load

Sensing — Maximum Pressure (no flow)

.

3

5

4

1

P A

2

7

6

T

A275770

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

5 — 8

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 8

Neutral Circuit Pressure

Pressure Generated by

Operation of a Service

Trapped Oil

Exhaust

13

9803/3280

P LS

2

1

8 7

11

6

4

3

5

12

10

T

A

9

P

A275750

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

5 — 9

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

5 — 9

Hydraulic Pump — Variable Flow

Pressure/Flow Regulator Valve

Load Sensing — Maximum Pressure (no flow)

When a service ram reaches the end of its stroke or the service meets resistance (for instance tearing out), the signal pressure from the loader (or backhoe) valve

13

will increase to the same pressure as pump output pressure.

The force of spring

6

is sufficient to move spool

4

down. The pressure in the system is also sufficient to move spool

3

up against the force of spring

12

, this creates a connection from the pump outlet to control piston

7

via port

A

.

Cont rol p ist on

7

moves t hus d ec reasing t he angle of swashplate

2

. Pump output flow now decreases whilst the system pressure is maintained at maximum setting. There is now no flow but maximum system pressure.

3

5

4

P A

7

6

12

T

2

1

A275780

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 1

Component Key:

B

Parallel gallery

C

Gallery

D

Drilling

T

Tank Port

1A

Pump Inlet (section P1)

1B

High Pressure Carry Over

1C

Pump Inlet (section P2)

3B

Main Relief Valve

3C

LIft Ram Spool

3D

Shovel Ram Spool

3E

Auxiliary Spool

3L

Unloader Valve Spool

3M

Unloader Pilot Valve

3N

Check Valve

3P

Spring Cavity

3Q

Solenoid Valve

9803/3280

Section E

6 — 1 Circuit Descriptions

Loader Valve — Neutral Circuit

The loader valve is mounted on the chassis frame, right hand side (when viewed from the rear).

It includes the lift ram spool

3C

, shovel ram spool

3D

and auxiliary spool

3E

. Linkage rods connect the spool ends to the control levers.

In neutral circuit hydraulic oil from the pump section

P2

enters the loader valve at

1C

via the steering priority valve

.

On entering the valve block, oil flows around the waisted section of the unloader valve

3L

, past check valve

3N

and joins the flow from pump section

P1

.

Oil from pump section

P1

enters the loader valve at

1A

.

Combined oil flow from

P1

and

P2

passes the main relief valve (MRV)

3B

and fills the parallel gallery

B

. From the parallel gallery the oil flows around the waisted central portions of spools

3C

,

3D

and

3E

(all in neutral position) and flows on to feed the excavator valve via high pressure carry over line

1B

.

Pressure in inlet gallery

C

is sensed by pilot valve

3M

via the bore of spool

3L

. At pressures below the setting of the unloader valve, both pilot valve

3M

and spool

3L

remain closed.

Loader Valve — Unloader Operation

Unloader spool operation protects the engine from being overloaded if a service is being worked particularly hard, for example when using the excavator to tear out. It does this by dumping the oil from the pump section

P2

to tank, allowing engine power to be applied fully to the main pump section

P1

.

If the pressure in the inlet gallery

C

rises to the setting of the pilot valve

3M

, this valve will open, allowing oil in spring cavity

3P

to escape more quickly than it can be replaced by oil entering through the small drilling

D

.

This creates a pressure differential between the spring cavity

3P

and gallery

C

. Higher pressure in gallery

C

acts on the face of spool

3L

causing the spool to be moved off its seat.

Oil entering the valve block from pump section

P2

now flow directly to tank

T

.

High pressure in gallery

C

also holds check valve

3N

firmly closed, preventing oil from pump section

P1

from also being dumped.

When pressure in inlet gallery

C

falls, for example if the excavator has stopped tearing out, pilot valve

3M

will close.

This means oil in spring cavity

3P

will be at the same pressure as oil in gallery

C

, spring pressure will move spool

3L

back onto its seat, closing pump section

P2

connection to tank.

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

6 — 2

1C(P2)

3B

3M

B

3L

Circuit Descriptions

3C

3D

3E

C

1B

T

Section E

6 — 2

3Q

1A(P1) 3N

3J

3L

3M

3P

A401150

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

T

C

P2

D

9803/3280

3N P1

A401160

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 3

Section E

6 — 3 Circuit Descriptions

3D

3M

3L

3P

W

3C

3E

1C(P2)

C

1A(P1)

3N

3J

3Q

T

A401170

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 4 Circuit Descriptions

Loader Valve

— Hydraulic Speed Control (HSC)

Solenoid valve

3Q

allow s t he op erat or t o c ont rol t he unloader spool movement (to dump flow from the hydraulic pump section

P2

) using a switch. There are two main applications for this operation:

1

More tractive force can be applied to the loader end when entering a stock pile. This is because more power is available from the engine as flow from pump section

P2

is being dumped directly to tank.

2

More power can be made available from the engine whilst the machine is travelling on the highway. Again, this is because flow from pump section

P2

is being dumped directly to tank.

When the solenoid valve

3Q

is de-energised its spool is moved by spring pressure. This spool movement makes a connection from the unloader spool chamber

3P

to tank.

Because the unloader chamber is now connected to tank, and so at exhaust pressure, pressure in gallery

C

(neutral shown) acts on the face of unloader spool

3L

causing the spool to be moved off its seat. Oil entering the valve block from pump section

P2

now flows directly to tank.

When solenoid valve

3Q

is energised its spool closes the connection from the unloader valve spool chamber to tank.

Spool

3L

is once again controlled by system pressure.

Component Key:

B

Parallel gallery

C

Gallery

D

Drilling

T

Tank Port

1A

Pump Inlet (section P1)

1B

High Pressure Carry Over

1C

Pump Inlet (section P2)

3B

Main Relief Valve

3C

LIft Ram Spool

3D

Shovel Ram Spool

3E

Auxiliary Spool

3L

Unloader Valve Spool

3M

Unloader Pilot Valve

3N

Check Valve

3P

Spring Cavity

3Q

Solenoid Valve

Section E

6 — 4

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 5

Component Key:

1A

Pump Inlet

B

Parallel Gallery

D

Service Line

3C

Lift Ram Spool

3J

Load Hold Check Valve

33

Lift Ram

34

Lift Ram

Section E

6 — 5 Circuit Descriptions

Loader Valve — Load Hold Check Valves

Operation 1

The illustration shows ‘arms raise’ being selected by the lift ram spool

3C.

The weight of the loaded shovel, as indicated by the arrows, produces a higher pressure in service line

D

than in the parallel gallery

B

.

This pressure differential causes load hold check valve

3J

to close, thus preventing the load from dropping.

Operation 2

As the neutral circuit has been blocked by the central land of the selected spool

3C,

the pressure in parallel gallery

B

increases until it is greater than that in service line

D

.

At this point, load hold check valve

3J

opens, allowing oil to flow from the parallel gallery into the service line and operate the lift rams

33

and

34

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 6

Section E

6 — 6 Circuit Descriptions

3J

3C

B

1A

3J

3C

D

B

33

34

A396410

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

1A

9803/3280

D

Purchased from www.WorkshopManuals.co.uk

A396420

33

34

Issue 1

Section E

6 — 7

Section E

6 — 7 Circuit Descriptions

D

3J

3C

C

B

1A

A

3C

E

33

34

A396390

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

9803/3280

A

A396400

Purchased from www.WorkshopManuals.co.uk

33

34

Issue 1

Section E

6 — 8 Circuit Descriptions

Loader Valve

Arms Lower

When a spool is selected as shown at

3C,

the central land of the spool

C

blocks the neutral circuit. Oil from the pump, entering at

1A

, is diverted into the parallel gallery

B

, opens the load hold check valve

3J

, and flows around the waisted section of the spool

D

and out to the rod side of lift rams

33

and

34

.

The lower land of the selected spool

E

blocks the flow from the parallel gallery to the head side port and oil returning from the rams is diverted into the exhaust gallery.

Component Key:

A

Spool Waists

B

Parallel Gallery

C

Central Land

D

Spool Waist

E

Lower Waist

1A

Pump Inlet

3C

Lift Ram Spool

3J

Load Hold Check Valve

33

Lift Ram

34

Lift Ram

Section E

6 — 8

Float

The float facility is provided to allow the arms to move up and down so that the shovel can follow the surface contours as the machine is driven over uneven ground.

This is achieved by moving the lift spool

3C

down beyond

‘arms lower’ into the ‘float’ detent, when the feed from the parallel gallery to the service ports is blocked and the neutral circuit is re-opened. Both service ports are connected to exhaust via the spool waists

A

.

Oil can then be displaced from either end of the lift rams

33

and

34

into the exhaust gallery, allowing the rams to open and close as required.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 9

Component Key:

1A

Pump Inlet

3C

Lift Ram Spool

3D

Shovel Ram Spool

3F

ARV — Head Side

3G

ARV — Rod Side

31

Shovel Ram

32

Shovel Ram

Circuit Descriptions

Loader Valve — A.R.V. Operation

Section E

6 — 9

Under normal operating conditions, with the shovel in the

‘ carry’ position, the mechanical linkage keeps the shovel level as the arms are raised, to prevent spillage of the load.

If, as illustrated, the shovel is fully tipped when the arms are being raised, the shovel is unable to tip further, producing back pressure in the head side of the shovel rams

31

and

32

and cavitation in the rod side.

As the arms continue to rise, the back pressure increases until it reaches the setting of A.R.V.

3F

. This A.R.V. then opens, allowing the excess back pressure to be dumped to exhaust and prevent the rams and linkage from being damaged.

The rod side A.R.V.

3G

senses a higher pressure in the exhaust gallery than in the service port and therefore opens to allow exhaust oil to overcome the cavitation.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 10 Circuit Descriptions

Section E

6 — 10

3G

3C

3F

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

9803/3280

Purchased from www.WorkshopManuals.co.uk

32

31

1A

A396370

Issue 1

Section E

6 — 11

Section E

6 — 11 Circuit Descriptions

A

D

H

F

G

D

E

A

C

F

2

1A

B

E

A

D

C

3B

1A

3

1A

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

1

3D

A401180

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

6 — 12 Circuit Descriptions

Main Relief Valve (MRV) — Operation

The main relief valve (M.R.V.)

3B,

situated in the loader valve b loc k, p rovid es c ont rol of b ot h load er and exc avat or pressures.

1 Valve at Rest

The illustration

1

shows a loader service selected by spool

3D

causing pressure to rise in the service line and back through the loader valve to the pump via line

1A

. The service is op erat ing und er light load and t he p ressure is not sufficient to cause any response in the M.R.V.

The main plunger

A

is held on its seat

B

by the combined effect of spring

C

and the pump pressure which enters chamber

D

through the small drilling

E

. Pump pressure outside the chamber is not high enough to lift the plunger off its seat.

2 Pilot Valve Opens

If, as shown in view

2

, pump pressure rises high enough to force the pilot valve

F

from its seat (against spring

G

), the pressure in chamber

D

is vented into the exhaust gallery

H

.

Unless the pressure continues to rise, plunger

A

will remain on its seat.

3 Valve Moves off its seat

In view

3

, pump pressure at

1A

has risen to the setting of the main relief valve but pressure in chamber

D

has not risen because the seat orifice of pilot valve

F

is larger than small drilling

E

and oil is unable to fill the chamber as quickly as it is being exhausted.

Pressure acting on the upper faces of main plunger

A

is therefore greater than the combined force of spring

C

and the pressure in chamber

D

. The plunger then moves off its seat, allowing pressure to be released to the exhaust gallery.

As the pump pressure decreases, the pilot valve is able to reseat and pressure in chamber

D

assists spring

C

to force the main plunger

A

back onto its seat.

Component Key:

A

Main Plunger

B

Valve Seat

C

Spring

D

Chamber

E

Drilling

F

Pilot Valve

G

Spring

H

Exhaust Gallery

1A

Pump Inlet

3B

Main Relief Valve

3D

Shovel Ram Spool

Section E

6 — 12

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

7 — 1

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 1

Loader Valve — Variable Flow

Operation

The loader valve is mounted on the chassis frame, right hand side (when viewed from rear).

It is a stack type, directional control valve that is configured for closed centre operation. The valve block comprises two or three service valve sections and a priority steer inlet section.

When operated, the designated valve section controls the volume and direction of oil by way of service ports

A

or

B

. A constant flow is maintained regardless of changing load pressures.

While the spools are in neutral position, the primary shuttles and secondary shuttles are vented to tank. When a spool is operated, the load pressure sensed at the work port is directed via the primary and secondary shuttles to the hydraulic pump, where the pump subsequently ‘swashes’ to meet this load sense demand.

Component Key:

7

8

9

10

11

12

13

1

4

5

2

3

6

Auxiliary (optional) spool

Shovel spool

Arms lift spool

Pump inlet

Tank port

Load sense port (from valve blocks)

Priority load sense port (from steer unit)

Priority work port (to steer unit)

Load sense carry over port (to backhoe valve)

Service ports

Auxiliary relief valve (rods side)

Auxiliary relief valve (head side)

Priority relief valve †

† Note:

Steer circuit pressure is controlled by a relief valve housed in the hydraulic steer unit (refer to Section H

Steering

). The priority relief valve housed in the loader valve must be set at 2500 lb/in

2

, this will ensure it does not interfere with the operation of the relief valve housed in the hydraulic steer unit.

9

9803/3280

3 2 1

!

0 0

0

0

0

0

@

8

£

Purchased from www.WorkshopManuals.co.uk

4

5

7

6

A273670

Issue 1

Section E

7 — 2

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 2

Loader Valve — Variable Flow

Priority Inlet Section Operation

The priority inlet section houses the steering priority valve and a relief valve assembly. Operation is as follows:

Steering

When the steering wheel is turned, a priority pressure demand signal is sent from the hydraulic steer unit and received at the priority inlet section (port

PRLS

). The signal oil flows through port

A

into chamber

C

via gallery

B

.

The combined force of spring

D

and signal oil pressure moves spool

E

up. The position of the spool now allows oil from the pump inlet port

P

to flow out to the hydraulic steer unit via priority work port

PR

.

It must be noted that relief valve assembly

J

is redundant.

This relief valve is part of the inlet section, however the hydraulic steer unit also houses a steer system relief valve.

To ensure the relief valve in the hydraulic steer unit controls the steer system pressure, valve

J

is set abnormally high

(172 bar; 2500 lb/in

2

).

Component Key:

P

T

LS

Pump Inlet

Tank

Load sense port (to pump)

PRLS

Priority Load Sense Port (from steer unit)

PR

Priority Work Port (to steer unit)

P

PR

PRLS

EXHAUST

PUMP

LOAD SENSE

LS

T

A273940

9803/3280

A

E

C

D

B

J

Purchased from www.WorkshopManuals.co.uk

A273930

Issue 1

Section E

7 — 3

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 3

Loader Valve — Variable Flow

Priority Inlet Section Operation

Service Selected (no steering demand)

If the steering is not selected, there will be no pressure demand signal in chamber

C

. Pump pressure is ‘dead ended’ at the steer unit, this pressure is felt in chamber

F

via priority port

PR

and drilling

G

. The pressure is sufficient to force spool

E

down against the force of spring

D

. The position of the spool now allows oil from the pump inlet port

P

to flow into passage

H

and on to the selected service via the valve block service ports.

Component Key:

P

T

LS

Pump Inlet

Tank

Load sense port (to pump)

PRLS

Priority Load Sense Port (from steer unit)

PR

Priority Work Port (to steer unit)

PR

P

9803/3280

EXHAUST

PUMP

LOAD SENSE

PRLS

LS

T

A273970

G

F

C

D

J

E

H

4

A273980

Issue 1

Purchased from www.WorkshopManuals.co.uk

PUMP

B

K

L

OAD

ENSE

Section E

7 — 4

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 4

Loader Valve — Variable Flow

Auxiliary Spool

The auxiliary valve section comprises the spool assembly

A

, load hold check valve assembly

B

, primary and secondary shuttles, items

L

and

K

respectively.

While the spools are in neutral position, the primary shuttles and secondary shuttles are vented to tank. When a spool is operated, the load pressure sensed at the work port is directed via the primary and secondary shuttles to the hydraulic pump, where the pump subsequently ‘swashes’ and increases its output to meet this load sense demand.

When a service is selected (the spool moved up or down), the waisted sections of the spool connect passage

C

to one of the service ports

D

. Oil from the pump must overcome the force of spring

E

to lift poppet

F

and make the connection from the pump passage

J

to the service ports

D

via passage

C

.

In some instances there is a back pressure in the service line

(e.g. generated by the weight of a loaded shovel). This pressure is felt in chamber

G

via drilling

H

in poppet

F

. The back pressure combined with the force of spring

E

keeps the load hold check valve firmly closed, preventing the load from dropping.

The pressure in pump passage

J

will increase until it is greater than that in the service line. At this point, the load hold check valve will open, as previously described.

A

B

G

E

H

F

J

C

A276100

A

K

L

9803/3280

A276290

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

7 — 5

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 5

Loader Valve — Variable Flow

Loader Shovel Spool

The loader shovel spool operates in the same manner as the auxiliary spool, refer to

Auxiliary Spool

.

The shovel valve section also houses auxiliary relief valves

(items

30

and

30A

).

Under normal operating conditions, with the shovel in the

‘ carry’ position, the mechanical linkage keeps the shovel level as the arms are raised, to prevent spillage of the load.

If, as illustrated, the shovel is fully tipped when the arms are being raised, the shovel is unable to tip further, producing back pressure in the head side of the shovel rams and cavitation in the rod side.

As the arms continue to rise, the back pressure increases until it reaches the setting of A.R.V.

30A

. This A.R.V. then opens, allowing the excess back pressure to be dumped to exhaust and prevent the rams and linkage from being damaged.

The rod side A.R.V.

30

senses a higher pressure in the exhaust gallery than in the service port and therefore opens to allow exhaust oil to overcome the cavitation.

The shovel service may also be fitted with a ‘return to dig’ detent solenoid

12

.

30

30A

12 A278920

PR

P

PRLS

LS

T

9803/3280

30A

30

Purchased from www.WorkshopManuals.co.uk

A279300

Issue 1

Section E

7 — 6

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 6

Loader Valve — Variable Flow

Loader Lift Spool

The loader lift spool operates in the same manner as the auxiliary spool, refer to

Auxiliary Spool

.

The lift service spool (item

18

) has a ‘float’ detent position.

The float facility is provided to allow the arms to move up and down so that the shovel can follow the surface contours as the machine is driven over uneven ground.

This is achieved by moving the lift spool

18

down beyond

‘arms lower’ into the ‘float’ detent. Both service ports are connected to exhaust via the spool waists

A

.

Oil can then be displaced from either end of the lift rams and into the exhaust gallery, allowing the rams to open and close as required.

18

A

A

A278910

P

18

9803/3280

A279430

T

LS

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

7 — 7

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

7 — 7

Loader Valve — Variable Flow

Shuttle Valve Signal Network

Each control valve section has two shuttle valves. Each valve compares two pressure signals. One of the shuttles is the primary

18

and the other is the secondary

17

.

The p rimary shut t le

18

c omp ares t he p ressure signal between the two service ports

A

and

B

in each valve section, the head and the rod pressure of the cylinder. In the example shown the boom service

37

port

B

pressure signal is greater than port

A

. Primary shuttle

18

moves across, the pressure signal is the highest shuttle pressure. This signal pressure passes to the next shuttle.

The secondary shuttle operates the same as the primary shut t le b ut c omp ares p ressure signals b et w een valve sections.

The signal network is arranged in series. It starts at loader valve block

9

inlet section which is connected to the steer valve

45

. The last secondary shuttle in the loader valve block is connected to the first secondary shuttle in the backhoe valve block

25

. The highest shuttle signal pressure from the loader valve block goes to the backhoe valve block.

The highest shuttle signal pressure is felt at the hydraulic pump which instructs the pump to vary the output to meet the highest shuttle load requirement. The stand-by pressure sp ool in t he p ump ad d s margin p ressure t o t he load requirement. The single highest shuttle signal pressure plus margin pressure governs pump output.

The pump will not change output until the shuttle network identifies a different shuttle signal.

37

A

B

P

18

30

17

LS T

45

STEER VALVE

P

PUMP

9803/3280

9 LOADER VALVE

37

B A

18

17

25 BACKHOE VALVE

Purchased from www.WorkshopManuals.co.uk

A316510

Issue 1

Section E

8 — 1

Component Key: (JCB ‘X’ Control Pattern)

A

Inlet

B

Parallel Gallery

C

Load Hold Check Valves

4A

Slew Spool

4B

Boom Spool

4C

Stabiliser Spool

4D

Stabiliser Spool

4E

Dipper Spool

4F

Bucket Spool

Section E

8 — 1 Circuit Descriptions

Excavator Valve

Manual Control — Neutral Circuit

Oil from the loader valve enters the excavator valve at

A

and flows through the neutral gallery and around the waists of the solid spools. It also fills the parallel gallery

B

but is not at a high enough pressure to open the load hold check valves

C

.

Note:

Machines with ISO control pattern have the boom and dipper spools interchanged.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 2 Circuit Descriptions

Section E

8 — 2

A

4A

4B

4C 4D

4E

4F

C

9803/3280

A401190

B

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 3

4B

Circuit Descriptions

B

4S

D

Section E

8 — 3

4B

9803/3280

4S

E

A401210

Purchased from www.WorkshopManuals.co.uk

A401200

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

Issue 1

Section E

8 — 4 Circuit Descriptions

Excavator Valve — Load Hold Check Valves

Operation 1

Flow to the service via a typical solid spool

4B

is controlled by the load hold check valve

4S

which is a spring-loaded non-return valve operating across the pressure feed from the parallel gallery

B

. The valve prevents reverse flow from the rams int o t he p ressure feed line, so maint aining ram pressure until exceeded by system pressure. The illustration shows a service selected but back pressure

D

exceeds system pressure which closes the load hold check valve

4S

.

Component Key:

B

Parallel Gallery

D

Service Line

4B

Spool

4S

Load Hold Check Valve

Section E

8 — 4

Operation 2

When pressure in the feed line exceeds back pressure, the load check valve

4S

opens and oil operates the ram. The remaining load hold check valves are also opened by system pressure but the galleries are dead-ended because the spools are in neutral.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 5

Section E

8 — 5

Componet Key:

C

Lower Service Port

D

Upper Service Port

E

One Way Restrictor

X

Parallel Gallery

4A

Slew Spool

4B

Boom Spool

4H

ARV

4J

ARV

Slew Ram End Damping

Circuit Descriptions

As ram

A

nears the closed position, damping rod

B

seats in cone

C

, where it is held by spring

D

. Tapered flutes on the end of the rod produce a restricting orifice, thus restricting the speed of the oil being exhausted from the ram. This provides a cushioning effect between the piston and the dump end of the ram, effectively damping out the shock loads which would otherwise occur when the boom reaches the end of its slewing arc.

Excavator Valve

— One Way Restrictor Operation

Because of its weight, the excavator end could take over control when boom lower was selected. The falling boom would tend to push oil out of the ram faster than the head side was being filled. Consequently, when the excavator had reached the ground, there would be a time lapse while the ram filled with oil before the service would operate again.

To prevent this from happening, the boom service is fitted with a one way restrictor. When the boom is being raised, t he p op p et in rest ric t or

E

is held off it s seat b y t he pressurised oil flow, therefore oil delivery to the boom ram rod side is unrestricted.

When the boom is being lowered, the oil flow through the one way restrictor

E

re-seats the poppet, therefore the flow of oil is restricted through the small drilling in the base of the poppet. This slows the boom down to a controllable speed.

D

A

w

B

Excavator Valve — Slew Operation

The illustration shows R.H. slew selected. The lower port

C

has been pressurised by the spool. Oil flows from the parallel gallery

B

, out past A.R.V.

4H

to both the head side of the L.H. slew ram and the rod side of the R.H. slew ram.

The boom therefore slews to the right hand side of the machine. Displaced oil from the rod side of the L.H. slew ram and from the head side of the R.H. slew ram flows back through the upper service port

D

and back to tank.

C

A230420

A

Ram

B

Damping Rod

C

Cone Seat

D

Spring

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 6 Circuit Descriptions

Section E

8 — 6

E

9803/3280

4A

4J

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A396350

A390630

D

B

C

4H

Purchased from www.WorkshopManuals.co.uk

A401220

Issue 1

Section E

8 — 7

4A

4J

Circuit Descriptions

Section E

8 — 7

4H

4E

4N

4E

4F

4Q

Key to Oil Flow & Pressure

Full Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

9803/3280

4M

4P

Purchased from www.WorkshopManuals.co.uk

A396430

Issue 1

Section E

8 — 8 Circuit Descriptions

Excavator Valve — Slew A.R.V. and Anti-

Cavitation Operation

The spool

4A

is in neutral but the momentum of the slewing excavator end creates back pressure in the head side of the

R.H. slew cylinder and in the rod side of the L.H. slew cylinder. This opens A.R.V.

4J

and dumps oil to exhaust. At this point the cylinders cavitate and exhaust oil pressure causes A.R.V.

4H

to open, allowing oil from the exhaust gallery to fill the L.H. cylinder.

Componet Key:

4A

Slew Spool

4E

Dipper Spool

4F

Bucket Spool

4H

ARV

4J

ARV

4M

ARV

4N

ARV

4P

ARV

4Q

ARV (option)

Section E

8 — 8

Excavator Valve — A.R.V. Operation

The illustration shows the bucket spool

4F

selected to operate the service against an immovable object. This forces the dipper away from the obstruction and pressurises the head side of the dipper ram.

When this pressure reaches the setting of A.R.V.

4M

, this valve opens, relieving the pressure into the exhaust gallery.

Cavitation occurs in the rod side of the dipper service until

A.R.V

4N

opens, allowing the higher pressure in the exhaust gallery to supplement that in the service line.

No t e: A.R.V.

4Q

is o nly f it t ed t o m ac hines w it h a

Rockbreaker.

For a further detailed description, refer also to

Pilot —

Operated Pressure Relief Valve Operation

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 9

Section E

8 — 9 Circuit Descriptions

Pilot — Operated Pressure Relief Valve

Operation

Component Key:

A

Service Pressure

B

Poppet

C

Piston

D

Spring

E

Poppet

F

Spring

G

Locknut

H

Cavity

J

Sleeve

K

Exhaust Cavity

L

Cavity

1 Valve at Rest

A.R.V’s are positioned in the excavator valve block in order to relieve excessive pressure in the services as described in

Excavator Valve — ARV Operation

.

When the service is in neutral and there are no excessive forces acting on the equipment, service pressure at

A

will be acting on the lower face of poppet

B

and will also be felt inside the valve via hollow piston

C

.

The force of springs

D

and

F

, combined with the service pressure acting on the upper faces of poppet

B

and piston

C

, keeps poppets

B

and

E

tightly seated.

The force of spring

F

is adjustable to suit the relevant service by means of adjuster screw and locknut

G

.

2 Pilot Valve Opens

As service pressure reaches the pilot setting of the valve, pilot poppet

E

lifts, allowing oil to escape into cavity

H

and pass down the sides of sleeve

J

into the exhaust gallery

K

.

3 Main Poppet Opens

As service pressure continues to rise and oil escapes from cavity

L

, the pressure differential between the upper and lower surfaces of piston

C

causes this piston to rise and seat on the point of pilot poppet

E

.

Oil continues to escape from cavity

L

but the incoming flow to the cavity has been cut off. This produces a pressure drop above poppet

B

, causing the poppet to lift and release service pressure into exhaust gallery

K

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 10

Section E

8 — 10 Circuit Descriptions

K

B

A

1

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

G

F

E

D

C

A

2

K

F

H

E

J

K

E

L

D

C

B

A

3

A390480

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 11

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 11

*

Excavator Valve — Manual Control

Hydraclamp Valve Operation

(Sideshift Machines)

When the backhoe is being used for excavating duties, the kingpost assembly must be ‘clamped’ to the sideshift rearframe.

The hydraclamp control valve assembly (items

G

,

D

and

C

) is positioned in the inlet end of the excavator valve block and is connected directly to the parallel gallery

B

. The valve operates in conjunction with solenoid valve

E

housed in the side of the excavator valve block.

1 — Clamps Pressurised

When the hydraclamp switch

A

is in the OFF position (not pressed), the solenoid valve

E

is de-energised. The solenoid valve in this de-energised state blocks the exhaust path from the parallel gallery

B

to the drain port (tank).

When an excavator service is operated, pressure is generated in parallel gallery

B

, this pressurised oil enters the clamp valve

C

and lifts poppet

D

off its seat against the force of spring

G

. The oil flows past the poppet and out to the hydra-clamps

62

.

2 — Clamps Released — Not Precision Control Machines

When the hydraclamp switch

A

is in the ON position

(pressed down), the solenoid valve

E

is energised. The solenoid valve in this energised state now allows a connection to be made from the parallel gallery

B

to the drain port (tank) via gallery

F

.

Oil from the hydra-clamps is vented through the clamp valve and gallery

F

to the drain port (tank).

Also, pressure resulting from the operation of an excavator service passes by poppet

D

as before but the oil takes the path of least resistance and is vented via gallery

F

to the drain port (tank).

Restrictor

H

ensures that not all oil in gallery

B

is dumped back to tank.

3 — Clamps Locked Up

If no service is being operated, pressure in the parallel gallery falls to that of the neutral circuit and the force of spring

G

is sufficient to keep the poppet seated.

Pressure is therefore trapped in the line to the clamps, maintaining the excavator end in a securely clamped condition.

H

D

C

A

G

B

9803/3280

F

DRAIN

PORT

CLAMP

PORT

E

E

S270680

62

Purchased from www.WorkshopManuals.co.uk

A270690

Issue 2*

Section E

8 — 13

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 13

Excavator Valve

Precision Control (Servo)

*

(Machines up to serial no. 931159)

Component Key:

A

Inlet Port

B

Outlet Port

C

Centering Spring

D

Integral Load Sensing Valves (Isolator Compensator

Spools)

E

Bypass Compensator Valve

F

Load Sense Drain Regulator and Relief Valve

G

Hydra-clamp Solenoid Valve

H

Pilot Operated Check Valve

J

Load Sense Drain Port

4A

Slew Spool

4B

Boom Spool

4C

Stabiliser Spool

4D

Stabiliser Spool

4E

Dipper Spool

4F

Bucket Spool

4G

Aux. Spool (not used on some machine variants)

4G

4F 4E

4D 4C

4B

4A

C

E

B

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402510

Issue 2*

Section E

8 — 14

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 14

Excavator Valve

Precision Control (Servo)

(continued)

*

(Machines up to serial no. 931159)

In the interest of machine efficiency and consistent backhoe operation the excavator valve is of a closed centre design and incorporates load sensing valves

D

, for each service.

These features enable the valve to operate as follows:

No service is selected (all spools in neutral)

Oil from the loader valve high pressure carry over enters the excavator valve at the inlet port

A

. Oil flows across the bypass compensator spool assembly

E

and returns to tank from the outlet port

B

.

Servo Spool Actuation

When a service is operated servo pressure from the joystick control valve acts on the end of the relevant service spool

Eg.

4A

and displaces the spool proportionally against the force of the centering spring

C

, allowing the oil to flow to move the required service. When the servo pressure on the end of the service spool is reduced the force of the centering spring overcomes the servo pressure and the service spool will move back proportionaly to the central neutral position.

Note that spools

4G

,

4D

and

4C

are manually actuated.

When a Service is Selected

When one or more services are selected the load sense valves detect the service generating the highest pressure.

This causes the bypass compensator valve

E

to close and allow pump flow to the spools and service ports at sufficient pressure to move the load. The load sense valves

D

also incorporate check valves. These valves prevent the load falling back if the load pressure is greater than the pump pressure. The closed centre design ensures consistent service operation regardless of load.

For a full description of spool and load sense valve operation see

Load Sense (Isolator Compensator) Valve Operation

on the next page.

F

J

D D D D D D D

H

G

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402500

Issue 2*

Section E

8 — 15

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 15

E1

20 bar

2

LS = 0 bar

1

E

LOAD = 100 bar

3

R

T

P

PUMP = 20 bar

5

S

A402770

T

E

E1

20 bar

2

LS = 20 bar

1

P

PUMP = 40 bar

LOAD = 100 bar

U

H

3

4

R

5

S

A402780

T

E1

20 bar

E

2

LS = 100 bar

1

P

9803/3280

LOAD = 100 bar

U

H 3

4

R

PUMP = 120 bar

5

S

A402790

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Exhaust

Lock Up

Neutral

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 16

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 16

Excavator Valve

Precision Control (Servo)

(continued)

*

(Machines up to serial no. 931159)

Load Sense (Isolator Compensator) Valve

Operation

No service is selected (all spools in neutral)

With the spools in the neutral position oil from the pump

P

flows to each spool and is dead ended. This generates sufficient pressure (about 20bar) to overcome the spring

E1

and oil flows across the bypass compensator spool assembly

E

to tank. Note that oil from the pump also flows into the ‘auxiliary pump gallery’

1

. Oil from the ‘bridge galleries’

3

is vented to tank via a groove in the main spool

S

.

Any load on the service ram

R

is held by the main spool

S

.

Oil is also vented to tank from the load sense gallery

2

via the load sense drain regulator/relief valve

F

(see below).

Spool at point of operating a service

Pressure from the load on ram

R

enters the bridge gallery

3

via the service port

4

. Compensator check valve

H

is held down on its seat preventing the load moving. At the same time the isolator spool

U

lifts and allows oil from the auxiliary pump gallery

1

to flow into the load sense gallery

2

. Oil pressure builds in gallery

1

and the bypass compensator spool

E

begins to close under the action of the oil and spring

(

E1

) pressure. This causes the pump pressure to rise to a new value as follows:

Pump pressure = Pressure in load sense gallery

2

+ pressure from spring

E1

.

When the pressure in load sense gallery

2

reaches the load pressure, isolator spool

U

moves down and closes off the auxiliary pump gallery

1

from load sense gallery

2.

If the load pressure subsequently rises or falls, the isolator spool moves due to pressure imbalance and maintains the pressure in the load sense gallery

2

at the same pressure as the load pressure. The pressure in the load sense gallery

2

always bleeds to tank, again causing pressure imbalance and the isolator spool to move, allowing the pressure in the gallery to be ‘topped up’. This ensures that ‘pressure balance’ is always maintained.

It must be noted that the load sense gallery

2

is connected to all load sense valves (one for each service). The pressure in the gallery

2

will always be equal to the highest load from any of the backhoe services. The maximum load sense pressure is regulated by the load sense drain regulator/relief valve

F

(see below).

Spool fully operating a service

As the spool

S

is moved further oil from the pump is diverted into the central gallery

5

. If the pump pressure has risen sufficiently (to a pressure equal to the load + spring pressure

E1

) then check valve

H

moves up off its seat and allows oil to flow into bridge gallery

3

, and out to the ram

R

via service port

4

. Exhaust oil from the other side of ram

R

is diverted to tank.

F

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

8 — 17

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 17

Excavator Valve

Precision Control (Servo)

*

(Machines up to serial no. 931159)

Hydraclamp Valve Operation

When the backhoe is being used for excavating duties, the kingpost assembly must be ‘clamped’ to the sideshift rearframe.

The hydraclamp control valve assembly (items

G

,

D

and

C

) is positioned in the front face of the excavator valve block and is connected directly to the parallel gallery

B

. The valve operates in conjunction with solenoid valve

E

located in the bottom of the excavator valve block.

1 — Clamps Pressurised

When the hydraclamp switch

A

is in the OFF position (not pressed), the solenoid valve

E

is de-energised. The solenoid valve in this de-energised state blocks the exhaust path from the galleries

B

and

F

to the drain port T (tank).

When an excavator service is operated, pressure is generated in parallel gallery

B

, this pressurised oil moves piston

C

which pushes ball

D

off its seat against the force of spring

G

. The oil flows through restrictor

H

, past the ball and out to the hydra-clamps

62

.

2 — Clamps Released — Precision Control Machines Only

To enable clamps release, the hydraclamp switch

A

must be in the ON position

and

an excavator service must be operated.

With the hydraclamp switch

A

in the ON position (pressed down), the solenoid valve

E

is energised. Pressure resulting from the operation of an excavator service moves piston

C

which pushes ball

D

off its seat.

With ball

D

lifted and the solenoid valve in its energised state, oil from the hydra-clamps is vented through the clamp valve and gallery

F

to the drain port T (tank).

Also, pressure resulting from the operation of an excavator service passes through restrictor

H.

The oil takes the path of least resistance and is vented via gallery

F

to the drain port T

(tank).

Restrictor

H

ensures that only a small amount of oil from gallery

B

is dumped back to tank.

3 — Clamps Locked Up

If no service is being operated, pressure in the parallel gallery falls to that of the neutral circuit and the force of spring

G

is sufficient to keep the ball

D

seated. Pressure is therefore trapped in the line to the clamps, maintaining the excavator end in a securely clamped condition.

A

C

62

F

E

G D H C B

P

T

62

G

E

P

T

A402930

Issue 2* 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

8 — 18

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 18

Excavator Valve

Precision Control (Servo)

(continued)

(Machines from January 2003)

In the interest of machine efficiency and consistent backhoe operation the excavator valve is of a closed centre design and incorporates pressure compensating valves

F

, for each service.

These features enable the valve to operate as follows:

No service selected (all spools in neutral)

Oil from the loader valve high pressure carry over enters the excavator valve at the inlet port

A

. Oil flows across the flushing valve spool assembly

B

and returns to tank from the outlet port

C

.

Servo Spool Actuation

When a service is operated servo pressure from the joystick control valve acts on the end of the relevant service spool

D

and displaces the spool proportionally against the force of the centering spring

E

, allowing the oil to flow to move the required service. When the servo pressure on the end of the service spool is reduced the force of the centering spring overcomes the servo pressure and the service spool will move back proportionaly to the central neutral position.

When a Service is Selected

When one or more services are selected the pressure compensator valves

F

detect the service generating the highest pressure. This causes the flushing valve spool

B

to close and allow pump flow to the spools and service ports at sufficient pressure to move the load. Load hold check valves

G

prevent the load falling back if the load pressure is greater than the pump pressure. The closed centre design ensures consistent service operation regardless of load.

For a full description of spool and pressure compensator valve operation see

Load Sense — Pressure Compensator

Valve Operation

.

P

T

T

E

D

LS

A

B

G

F

G

A405000

9803/3280

C

A

M

T

P

C

T3

A A A A A A A

B

B B B B B B B T

M

T1

LS

P

A403680

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

8 — 19

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 19

Excavator Valve

Precision Control (Servo)

(continued)

(Machines from January 2003)

Load Sense — Pressure Compensator Valves

Operation

No service selected (all spools in neutral)

With the spools in the neutral position oil from the pump

P

flows to each service spool

S

and is dead ended. This generates sufficient pressure (about 15bar) to overcome the spring

E1

and oil flows across the flushing valve spool assembly

E

to tank

T

. Any load acting on the service ram

R

is held by the service spool

S

.

Oil in the load sense gallery

LS

is vented to tank across the flow regulator valve

F

.

The pressure compensator valve

PC

and load hold check valves

CV

are closed.

Operating a service

The service spool

S

is moved by servo pressure connecting the oil from the pump

P

to the gallery

P1

. The pressure in this chamber opens the pressure compensator valve

PC

allowing oil into the load sense gallery

LS

. Oil pressure builds in the gallery

LS

and the flushing valve spool

E

begins to close under the combined action of the oil pressure and spring force, causing the pump pressure to rise as follows:

Pump pressure = Pressure in load sense gallery

LS

+ pressure from spring

E1

.

When the pump pressure has risen sufficiently i.e. to a pressure equal to the load + spring pressure (15 bar) the load hold check valve

CV

moves off its seat and allows oil to flow into the service gallery

A

, initiating movement of the service ram

R

. Exhaust oil from the other side of the service ram is directed by the service spool

S

to tank.

The maximum load sense pressure and hence pump pressure is set by the load sense relief valve

G

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

8 — 20

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 20

M

LS

P

R

P

F

E

CV

E1

A B

PC

T

LS

T1

T

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

M

LS

P

P

G

E

E1

T

T1

T

CV

S

A

LS

A405030

B

R

PC

9803/3280

S

P1

Purchased from www.WorkshopManuals.co.uk

A405040

Issue 1

Section E

8 — 21

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 21

LS

PC

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

Bucket

Actuation

P1 P2

LS

A405050

PC

9803/3280

Bucket

Actuation

Boom

Actuation

Purchased from www.WorkshopManuals.co.uk

A405060

Issue 1

Section E

8 — 22

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

8 — 22

Excavator Valve

Precision Control (Servo)

(continued)

(Machines from January 2003)

Load Sense — Pressure Compensator Valves

Operation

Operating an individual service

It must be noted that the load sense gallery

LS

is connected to all the pressure compensator valves

PC

(one for each service) as shown. The pressure in the load sense gallery

LS

will always be equal to the highest load from any of the backhoe services.

The pressure compensator valves are fitted between each service spool and service ram and sense the pressure acting on either side of the particular service spool. The pressure compensator valve will move in response to the pressure drop (pressure differential) created across the spool.

When one service only is operated the pressure compensator valve

PC

is FULLY opened as shown, connecting the gallery

P1

to gallery

P2

and to the ram service port without any pressure drop.

Operating multiple services a) Normal Condition

When another service with a higher load is operated simultaneously, a typical example is the lifting of the boom and simultaneous operation of the bucket as shown.

The higher load pressure in the boom service causes the pressure compensator valve

PC

in the bucket service to partially close, reducing the size of the opening through which the oil must flow, and in this way maintains a pressure drop across the pressure compensator equal to the pressure drop across the bucket service spool.

In this example, because of the action of the pressure compensator valve the bucket service is always kept independant of the other services, the bucket ram speed remains constant (as controlled by the bucket service spool) and is not affected by the greater operating pressure in the boom service.

b) With insufficient flow from pump

Should the oil flow demanded by the sum of the combined services operating ever exceed that of the pump, all the pressure compensator valves will partially close accordingly, effectively dividing the available flow between all the services proportionally.

In this condition the service ram with the highest load will

NOT stop, because the speed of the other service rams operating will have been reduced proportionaly by the action of the pressure compensator valves to compensate.

When one of the service spools is returned to neutral, the speed of the other service rams still operating will all increase proportionally.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Smooth Ride System

1 www.WorkshopManuals.co.uk

1

4

3E 3F

3A

3J

3G

3D

3H

3C

3J

3B

3J

4

1

1

3

T

3

P1

T

P2

ACC

2

2

A391100

S307310

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Smooth Ride System

Sm oot h Rid e Syst em (SRS) w ill enhanc e t he comfort of the ride by damping out the forces imposed on the machine by the movement of the loader arms as the machine travels over uneven surfaces.

This is achieved by connecting the head side of the lo ad er arm s

1

t o a p ressurised p ist o n t yp e accumulator

2

.

When a switch in the cab is operated, selector valve

3

is energised and opens. Hydraulic oil from the piston head side is dead ended at the loader valve block

4

but is connected to the accumulator.

The rod side of the loader ram is connected to tank

T

via the selector valve to make up or dissipate oil as required.

Note:

The smooth ride system will not function on machines fitted with hose burst check valves.

Component Key:

1

Loader Lift Rams

2

Accumulator

3

Solenoid Valve Block

4

Loader Valve Block

T

Tank

Purchased from www.WorkshopManuals.co.uk

Section E

11 — 1

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 1

BOOM RAM

X

Y

E

C

Hose Burst Protection Valve

Boom & Dipper Operation

The small letter annotations

A

,

B, X

, and

Y

are stamped on the valve.

Operation 1 — Load Raise

When ‘dipper out’ is selected, oil from the excavator valve block is fed to port

B

, the oil opens check valve

C

against spring

D

and passes through internal galleries into the rod

(raise) side of the ram via port

Y

.

Oil from the head side of the ram enters at port

X

, opens check valve assembly

E

and returns to tank via port

A

and the excavator valve block.

A B

BACKHOE VALVE

A323040

BOOM RAM

X Y

A B

BACKHOE VALVE

E

A323041

Operation 2 — Load Lower

Oil from the excavator valve block is fed to port

A

. The connection to the head side of the ram is blocked by the check valve assembly

E

and the position of spool

F

.

A cross drilling

G

in the valve connects the

A

port gallery to cavity

J

. The pressure in cavity

J

increases to such a point that it moves spool

F

to the left against the force of spring

H

.

The new position of the spool creates a connection between the

A

port gallery and the head side of the dipper ram (via port

X

).

There is also a connection between the

Y

port gallery and the

B

port gallery. Oil from the rod side of the ram enters at port

Y

and returns to tank via port

B

and the excavator valve block.

Component Key:

C

Check Valve

D

Spring

E

Check Valve Assembly

F

Spool

G

Cross Drilling

H

Spring

J

Cavity

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

11 — 2

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 2

(A) (X) (B)

D

C

E

(Y)

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

H

E

(A) (X) (B)

G

F

(Y)

J

A395760

9803/3280

Purchased from www.WorkshopManuals.co.uk

A395770

Issue 1

Section E

11 — 3

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 3

(A) (X) (B)

H

J

F

K

(Y)

L

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

(A) (X) (B)

D

C

B

A

(Y)

A395780

9803/3280

Purchased from www.WorkshopManuals.co.uk

A395790

Issue 1

Section E

11 — 4

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 4

Hose Burst Protection Valve

Boom & Dipper Operation (Cont’d)

Operation 3 — Relief Valve

If during normal operation the pressure in the rod side of the dipper ram increases (for example, by the operation of the bucket against an obstacle), increasing pressure in the ram enters at port

Y

. The position of spool

F

prevents this increasing pressure from venting back to the tank. The pressure increases to such a point that it moves plunger

K

off its seat (to the right) against the force of spring

L

.

The new position of plunger

K

opens a connection to cavity

J

, the pressure is high enough to move spool

F

to the left against the force of spring

H

. The new position of the spool creates a connection from the rod side of the ram to port

B

.

Note that oil exhausted via port

B

will not reduce to low pressure until the A.R.V. in the excavator valve block also opens.

H

F

BOOM RAM

X

Y

A B

K

L

BACKHOE VALVE

A323042

Operation 4 — Hose Burst Condition

If a burst hose or other leakage occurs in the feed to the rod

(raise) side of the ram, check valve C will be kept firmly held on its seat by the back pressure generated due to the weight the load in the bucket and the force of spring

D.

Oil trapped between the valve and the ram will prevent movement of the load. To lower the load, see Lowering The

Load.

BOOM RAM

X

Y

Component Key:

C

Check Valve

D

Spring

F

Spool

H

Spring

J

Cavity

K

Plunger

L

Spring

A B

BACKHOE VALVE

E

C

A323043

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

11 — 5

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 5

C2

P

E

22

B

A

Hose Burst Protection Valve

Loader Operation

The small letter annotations

V2

,

C2, P

,

T

and

E

are the same as the port markings found on the HBPV.

Operation 1 — Load Raise

When lift is selected, oil from the loader valve block

9

is fed to port

V2

on the HBPV, the oil opens check valve sleeve

A

against spring

B

and passes through internal galleries into the (raise) side of the ram via port

C2

.

Oil from the lower side of the ram returns to tank via port

P

and the loader valve block.

V2

T

A323090

9

22

C

C2

P

L

9

J

D

T

G

V2

H

A323091

Operation 2 — Load Lower

Oil from the loader valve block

9

is fed directly to the (lower) side of the ram. A pilot line

C

from the service line is connected to the HBPV at port

P

.

Oil enters the HBPV at port

P

and passes through drilling

D

, down threads

F

and acts on the end face of piston

G

. The pressure is sufficient to move piston

G

to the right, thus moving plunger

J

off its seat against spring

H

. With the plunger off its seat, oil from the opposite side of the ram enters the HBPV at port

C2

, passes through the HBPV and returns to tank via port

V2

and the valve block.

A drilled hole

N

through the centre of plunger

J

connects chamber

Q

to atmosphere

T

, this prevents the pressure in chamber

Q

from rising to such a point that it would prevent any movement of plunger

J

.

Threads

F

and the one-way check valve ball

L

act as restrictors to ‘dampen’ any adverse effects of operating the control levers erratically.

Component Key:

A

Check Valve Sleeve

B

Spring

C

Pilot Line

D

Drilling

F

Thread

G

Piston

H

Spring

J

Plunger

L

Ball

N

Orifice

Q

Chamber

9

Loader Valve Block

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

11 — 6

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 6

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

(C2)

(P)

(E)

(T)

B A

9

(V2)

A395800

9803/3280

9

C

(C2)

(P) (T)

(V2)

(E)

L

D F G N B A J H Q

A395810

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

11 — 7

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 7

9

(C2)

(P)

(E)

(T)

(V2)

B A

J H

A395820

9

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

9803/3280

(C2)

(P) (T)

(V2)

(E)

K

L

G B

A J

H

A395830

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

11 — 8

www.WorkshopManuals.co.uk

Hydraulics

Circuit Descriptions

Section E

11 — 8

Hose Burst Protection Valve

Loader Operation (Cont’d)

Operation 3 — Relief Valve

If during normal operation the pressure in the ram increases

(for example, by the operation of the bucket against an obstacle), increasing pressure in the ram enters the HBPV at

C2

and will be sensed on the face of plunger

J

. When the force of spring

H

is exceeded, the plunger is made to move off its seat thus allowing oil to flow through the valve to port

V2

.

Note:

Oil exhausted via port

V2

will not reduce to low pressure until the A.R.V. in the valve block

9

also opens.

C2

P

J

22

H

T

V2

A323092

9

22

Operation 4 — Hose Burst Condition

In the event of a hose burst or other leakage in the feed to the HBCV, plunger

J

will be held on its seat by the force of spring

H

. Also, back pressure and the force of spring

B

will hold check valve seat

A

firmly against the plunger, thus trapping a column of oil in the head side circuit which will prevent the load from dropping.

Note that before the plunger can move onto its seat, the pressure on the pilot side of the piston

G

must vent to atmosphere quickly, therefore ball

L

will open against the force of spring

K

which allows the oil to vent down the threads AND through the drilling previously plugged by ball

L

.

C2

K

L

J

P

G

T

V2

H

A

B

9

A323093

Component Key:

A

Check Valve Seat

B

Spring

G

Piston

H

Spring

J

Plunger

K

Spring

L

Ball

9

Loader Valve Block

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

15 — 1

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 1

Hydraulic System

— Fixed Flow

Fault Finding Contents

Introduction

Lack of power in all hydraulic functions

All hydraulic rams slow to operate

One hydraulic service fails to operate or is slow to operate

The engine tends to stall when the hydraulics are under load

A spool is sticking

Leaking Oil Seal (Control Valves)

Ram creep

Hydraulic oil becomes too hot

Page No.

15 — 1

15 — 1

15 — 2

15 — 2

15 — 2

15 — 3

15 — 3

15 — 3

15 — 4

Introduction

The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have t rac ed t he f ault y unit , ref er t o t he ap p ro p riat e dismantling, inspecting and test instructions given elsewhere in the hydraulics section.

To help identify circuits, valves, rams etc mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section).

1

B ef o re yo u b eg in f ault f ind ing , read t he Saf et y information at the beginning of this manual.

2

Make simple checks before say, stripping a major component.

3

Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

4

What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

5

Make any relevant electrical checks before moving on to the hydraulics.

6

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

7

Rep lac e any seals suc h as ‘ O’ ring s b ef o re reassembling hydraulic components.

Fault Probable Cause

1

Lack of power in all hydraulic functions.

Insufficient hydraulic fluid.

Hydraulic leaks in system.

Engine performance.

Main relief valve (MRV) setting incorrect.

Low pump flow.

Hydraulic tank breather

Tank filter by-pass valve

Unloader valve pressure setting too high

Action

Check for leaks and top up as required.

Check hoses, replace as required.

Check engine performance, see transmission section for stall speed test procedures.

Check and adjust as required.

Check pump flow, if required service or replace pump.

Clean or replace the breather

Check condition of hydraulic filter

Check pressure setting of the unloader valve.

….. continued

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

15 — 2

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 2

Fault

2

All hydraulic rams slow to operate.

3

One hydraulic service fails to operate or is slow to operate.

Probable Cause

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Low pump flow.

Priority valve operating.

Check pump flow, if required service or replace pump.

Check if the priority valve is sticking, rectify as required.

Check and adjust as required.

Main relief valve (MRV) setting incorrect.

Unloader valve

Action

Check pipe lines and replace as required.

Tank filter by-pass valve

Hydraulic tank breather

Associated service pipe lines , leaking damaged, trapped or kinked.

Associated ram leaking.

Check if unloader valve is sticking, i.e.

dumping flow from pump section P2.

Check condition of hydraulic filter

Clean or replace the breather

Check hoses, replace as required.

Complete ram leakage check, replace seals as required.

Check and adjust as required. Auxiliary relief valve (ARV) setting incorrect.

Associated valve block section leaking or not operating.

Check for leaks, rectify as required.

Also, see fault

6

‘Leaking Oil Seal

(Control Valves)’.

Make sure that the associated load hold check valve is operating.

Check that the control lever and associated linkages is operating the spool, rectify as required. Also, see fault

5

, ‘A spool is Sticking’.

Test check valve, rectify as required.

Check valve malfunctioning

(if fitted, e.g. stabiliser circuit)

Hose burst protection valve

(if fitted) malfunctioning.

Piston rod is bent

Test HBPV, service as required.

M.R.V setting incorrect.

Replace piston rod, check pressure settings of MRV and ARV.

Check that associated pivot pins are adequately greased

Check and adjust as required.

4

The engine tends to stall when hydraulics are under load.

Poor engine performance.

Unloader valve pressure setting too high

Check engine performance, see transmission section for stall speed test procedures.

Check pressure setting of the unloader valve.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

15 — 3

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 3

Fault

5

A spool is sticking.

Probable Cause

Oil temperature abnormally high.

The hydraulic fluid is dirty.

Action

Check for correct fluid, see Lubricants and Capacities. Check oil cooler and grille for blockage.

Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system

Fill with clean hydraulic fluid.

Check tightening torque.

The service pipe connection is over tightened.

The valve housing was twisted during installation.

Pressure too high.

A control linkage is bent

A spool is bent

A return spring is broken.

A return spring or cap is out of alignment.

Temperature distribution within control valve not uniform.

Loosen retaining bolts and tighten to correct torque figures.

Check system pressure.

Disconnect the linkage. Repair the linkage if possible, or fit a new one

Dismantle the control valve. Renew spool as necessary.

Renew as necessary.

Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts

Warm the entire system up before using service.

6

7

Leaking Oil Seal (Control Valves)

Ram creep.

Paint or dirt on the seal face.

The back pressure in the valve circuit is excessively high.

Spool damaged.

The seal is not secured.

The seal is cut or damaged.

Associated ram or pipe lines from Check and rectify as required.

ram leaking.

Check valve malfunctioning

(if fitted, e.g. stabiliser circuit)

Test check valve, rectify as required.

Rectify, check for contamination.

Associated valve section spools leaking.

Associated ARV leaking Rectify, check for contamination .

Note:

Refer also to

Service Procedures, Ram Creep Tests — All Services

Remove the seal and clean.

Check circuit pressures, adjust if possible. Otherwise investigate thoroughly.

Dismantle. Inspect all parts. Renovate or renew as necessary.

Clean the seal and tighten the retaining bolts to the correct torque.

Fit a new seal.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

15 — 4

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 4

Fault

8

Hydraulic oil becomes too hot

Probable Cause

Oil cooler obstructed

Restriction in neutral circuit lines

Hydraulic filter clogged and by-pass valve not working

Action

Remove debris from cooler fins

Check hoses, replace as necessary

Change hydraulic filter

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

15 — 10

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 10

Hydraulic System

— Variable Flow

Introduction

Fault Finding Contents

This section details the possible faults that may be found with the loader and backhoe valve blocks. The faults listed only ap p ert ain t o valve b loc ks fit t ed on variab le flow hydraulic machine systems (Rexroth valves).

Page No.

Introduction

High or low system pressure

15 — 10

15 — 10

1

B ef o re yo u b eg in f ault f ind ing , read t he Saf et y information at the beginning of this manual.

2

Make simple checks before say, stripping a major component.

Pump stays at high pressure 15 — 10

Pressure or flow obtained at one port only

No pressure or flow at either port

15 — 10

15 — 10

3

Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

4

What ever t he f ault , c hec k t he c o nd it io n o f t he hydraulic fluid. Drain and replace if necessary.

High work port leakage

Leaks between sections

Sticking spool

Detent will not hold

Electrical detent will not hold

15 — 10

15 — 11

15 — 11

15 — 11

15 — 11

5

Make any relevant electrical checks before moving on to the hydraulics.

6

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

7

Rep lac e any seals suc h as ‘ O’ ring s b ef o re reassembling hydraulic components.

Poor performance, slow operating speed and/or low maximum stall speed 15 — 11

PROBLEM:

POSSIBLE CAUSE:

High or Low system pressure.

1) Wrong pressure and/or flow regulator valve settings. 2) Loss of pilot signal due to shuttle failure.

CORRECTIVE ACTION:

1) Readjust regulator valves. 2) Operate individual services to determine which shuttle is at fault, refer to

Service Procedures, Variable Flow Pumps, Shuttle Valve Signal Network —

Testing

.

PROBLEM:

POSSIBLE CAUSE:

Pump stays at high pressure.

1) Sticking main spool. 2) Sticking compensator spool.

CORRECTIVE ACTION:

1) See ‘Sticking Spool’ guide. 2) Remove & clean compensator spool.

PROBLEM:

POSSIBLE CAUSE:

Can only obtain pressure or flow at one port.

1) Dirt in primary shuttle or damaged o-ring.

CORRECTIVE ACTION:

1) Remove & clean shuttle, inspect o-ring and replace if required.

PROBLEM:

POSSIBLE CAUSE:

No pressure or flow at either port.

1) Dirt in secondary shuttle.

CORRECTIVE ACTION:

1) Shift one spool at a time with blocked ports until faulty section found, remove shuttle and clean, inspect o-ring and replace if required.

PROBLEM:

POSSIBLE CAUSE:

High work port leakage.

1) Spool not centred. 2) Dirt in port relief valve.

CORRECTIVE ACTION:

1) Check centring springs. 2) Remove & clean relief valve.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

15 — 11

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 11

PROBLEM:

POSSIBLE CAUSE:

Leaks between sections.

1) Missing or cut seals.

CORRECTIVE ACTION:

1) Disassemble valve stack and check for missing or cut o-rings.

PROBLEM:

POSSIBLE CAUSE:

Sticking spool.

1) Linkage binding. 2) Damaged spool. 3) Uneven torque of tie-rod. 4) Incorrect number of shims on tie-rods.

CORRECTIVE ACTION:

1) Check linkage. 2) Remove and inspect spool. 3) Loosen tie-rod bolts, check and re-torque. 4)

Disassemble and check that each tie-rod has one shim.

PROBLEM:

POSSIBLE CAUSE:

Mechanical detent will not hold.

1) Broken detent shaft.

CORRECTIVE ACTION:

1) Remove detent & inspect.

PROBLEM:

POSSIBLE CAUSE:

Electrical detent will not hold.

1) Current broken.

CORRECTIVE ACTION:

1) Check current going into detent.

PROBLEM:

POSSIBLE CAUSE:

Poor performance, slow operating speed and/or low maximum stall speed.

1) Blocked flow regulator spool.

CORRECTIVE ACTION:

1) Flow check, remove and clean flow regulator valve, refer to

Service Procedures, Variable

Flow Pumps — Regulator Valve Adjustment

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

15 — 12

www.WorkshopManuals.co.uk

Hydraulics

Fault Finding

Section E

15 — 12

Smooth Ride System

Fault Probable Cause Action

1

5

6

Unable to power down loader arms with system switched OFF.

2

Restricted loader arm suspension movement when switched ON.

3

Springy loader arm lift with system switched OFF.

4

No suspension, unable to power down when switched ON.

Accumulator gas pressure decrease.

Oil in gas side of accumulator.

Rod side solenoid valve open.

Check if solenoid operating, replace solenoid or selector valve as required.

Rod side solenoid valve closed.

Head side solenoid valve open.

Check if solenoid operating, replace solenoid or selector valve as required.

Check if solenoid operating, replace solenoid or selector valve as required.

Head side solenoid valve closed.

Check if solenoid operating, replace solenoid or selector valve as required.

Leak across accumulator piston.

Recharge, if frequent replace seals in accumulator.

Leak across accumulator piston.

Discharge, drain and recharge, if frequent replace seals in accumulator.

7

Increase in charge pressure.

Oil to gas leak across accumulator Discharge, drain and recharge, if frequent piston.

replace seals in accumulator.

Note

: It is normal for the loader arms to lift or lower slightly, when SRS is switched ON.

Check fuse A1 replace as required.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

20 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

20 — 1

Hydraulic Contamination

Hydraulic Fluid Quality

Construction machinery uses a large volume of fluid in the hyd raulic syst em for p ow er t ransmission, eq uip ment lubrication, rust prevention and sealing.

According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid.

Therefore, it is obvious that control of the quality of the hydraulic fluid helps prevent hydraulic equipment problems and greatly improves safety and reliability. Furthermore from an economic angle it extends the life of the hydraulic fluid if quality is maintained.

Effects of Contamination

Once inside the system, hydraulic circuit contaminants g reat ly ef f ec t t he p erf o rm anc e and lif e o f hyd raulic equipment. For example, contaminants in a hydraulic pump develop internal wear to cause internal leakage and hence lower discharges. Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of this and other equipment.

Contaminants also enter principal sliding sections of the equipment causing temporary malfunction, scuffing, sticking and leakage and can lead to major problems.

The main contaminants can be classified as follows:-

1 Solid Particles

— sand , fib res, met allic p art ic les, welding scale, sealing materials and wear particles etc.

2 Liquid

— usually w at er and inc omp at ib le oils and greases.

3 Gases

— Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.

These c ont aminant s c an ap p ear d uring manufac t ure, assembly and operation.

Cleaning Operation

The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit, as illustrated or similar. General Bulletin 011 also refers.

Procedure

Connect the cleaning unit in place of the hydraulic filter and run the system for sufficient time to pump all the hydraulic fluid through the unit. Disconnect the cleaning unit and reconnect the filter. Top up the system with clean hydraulic fluid as required.

Contaminant Standards

Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns.

1 micron= 0.001 mm (0.0000394 in)

Listed below are a few typical comparisons:-

Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)

Human Hair = 70 microns (0.07 mm, 0.00275 in)

Grain of Salt = 100 microns (0.1 mm, 0.00394 in)

Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.

St and ard s w ill oft en b e q uot ed t o ISO (Int ernat ional

St and ard s Org anisat io n) f o r w hic h lit erat ure c an b e obtained.

Filters

The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules.

To ensure o p t im um p erf o rm anc e and reliab ilit y it is important that the machines hydraulic system is serviced p erio d ic aly in ac c o rd anc e w it h t he m anuf ac t urers requirements. For service schedules refer to Section 3

Routine Maintenance

.

S168050

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

21 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

21 — 1

B

A

B

A

D

C

A396190

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

21 — 2

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

21 — 2

Fixed Flow Pumps

Flow and Pressure Testing

Before removing the pump it is necessary to determine the source of any problem by measuring the output flow at system pressure from both of the pump outlet ports.

To check flow it is necessary to fit flow meter

A

into the output line of each pump section in turn. If available, load valve

B

(service tool 892/00270) should also be installed (see

Note 1

). Make sure the flow meter is installed with its arrow pointing away from the pump and, if applicable, located between the pump and the load valve.

Note 1

: If no load valve is available, ignore the references to the load valve in

Fitting/Removing a Flow Meter and Load

Valve

below. An alternative method of determining flow is included in the Checking Flow procedures following.

Fitting/Removing a Flow Meter and Load

Valve

Before fitting/removing a flow meter and load valve, switch off the machine and operate the loader/excavator controls a few times to vent system pressure.

!

WARNING

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

!

WARNING

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

TRANS 1-2

Fitting

1 a

Pump section 1 — disconnect hose

C

from the pump. Fit the flow meter and load valve (see

Note

2

) between hose

C

and the pump.

b

Pump section 2 — disconnect hose

D

from the pump. Fit the flow meter and load valve (see

Note

2

) between hose

D

and the pump.

Note 2:

Make sure the load valve is in the open position, i.e.

with the adjusting knob screwed fully out, before carrying out the

Checking Flow

procedure.

Removing

Removing is the reverse of fitting.

Checking Flow

1

Check the setting of the Main Relief Valve (MRV) as described in

Loader Valve, Pressure Testing

. Adjust if necessary.

2 a

Using a load valve

— fit a flow meter and load valve, as described in Fitting, to each pump outlet in turn.

Fit a 0-400 bar (0-6000 lbf/in

2

) pressure gauge to the load valve pressure test connector.

b

If no load valve is available

— fit a flow meter, as described in Fitting, to each pump output in turn.

3

Start the engine and bring the hydraulics up to working temperature 50ºC (122ºF). Set the engine speed to

2200 rpm.

4 a

Using a load valve

— adjust the load valve so that the pressure gauge reading is just below the MRV setting.

b

If no load valve is available

— raise or lower the loader arms until the rams are fully open or closed.

Continue to operate the raise/lower control so that system pressure builds up. Watch the flow meter and not e it s read ing at t he moment t he M RV operates.

5

The flow reading should be as listed in

Technical

Data

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

22 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 1

Variable Flow Pumps

Flow and Pressure Testing

C

B

A

D

S315770

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

22 — 2

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 2

Variable Flow Pumps

Flow and Pressure Testing

Load Sensing Pressure

With no services operating, there should be no pressure in the load sense line, this is because hydraulic oil flows through the load sense circuit back to the hydraulic tank. If a shuttle valve is ‘stuck’, or a hose kinked, then a pressure could be induced in the load sense lines, this will have an effec t on t he hyd raulic syst em. To c hec k load sense pressure:

1

Warm the hydraulic oil to working temperature, i.e. 50°C

(122°F):

a

Set the engine speed to 2200 rev/min.

b

Operate the loader shovel dump service to blow off the auxiliary relief valve.

2

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

3

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

A

located on the load sense line from the loader valve.

4

Start the engine and run at 2200 rev/min.

5

Do not move the steering wheel and make sure that all control levers remain in ‘neutral’ position.

6

Check the pressure gauge reading, which should be as specified in

Technical Data

.

7

If the pressure is higher than specified, first move the steering wheel and then any of the service levers. If this does not reduce the pressure, physically check the load sense lines for trapping or kinking. As a last resort, the service valves may have to be removed and checked for sticking shuttle valves. However, this should not be done until all other checks have been completed.

8

Machines with the load sense pressure relief valve adjust the load sense pressure relief valve

E

. Machines without a load sense pressure relief valve adjust the regulator valve.

Stand-by Pressure

With the engine switched off, the pump swashplate is spring loaded to the full flow position. On engine start up standby pressure moves the swash plate to minimum flow position

(see descriptions). To check stand-by pressure:

1

Warm the hydraulic oil to working temperature, i.e.

50°C (122°F):

a

Set the engine speed to 2200 rev/min.

b

Operate the loader shovel dump service to blow off the auxiliary relief valve.

2

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

3

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

B

located on the pump pressure out line.

4

Start the engine and run at 2200 rev/min.

5

Do not move the steering wheel and make sure that all control levers remain in ‘neutral’ position.

6

Check the pressure gauge reading, which should be as specified in

Technical Data

.

7

If the pressure is not as specified, do not make any adjustments at this stage. Complete the other checks detailed in this section.

8

Refer to

Regulator Valve Adjustment

.

E

9803/3280

Purchased from www.WorkshopManuals.co.uk

S315770

Issue 1

Section E

22 — 3

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 3

Variable Flow Pumps

Flow and Pressure Testing (Cont’d)

Maximum Hydraulic Stall

With variable flow hydraulics the pump swashplate angle will inc rease or d ec rease ac c ord ing t o p ressure d emand .

However in situations of maximum hydraulic stall, i.e. ram full travel, the pressure in the circuit will achieve the setting of the pressure regulator spool. To check the setting:

Note

: Machines with a load sense relief valve, disconnect and blank the load sense relief valve

E

at

F

.

1

Warm the hydraulic oil to working temperature, i.e. 50°C

(122°F):

a

Set the engine speed to 2200 rev/min.

b

Operate the loader shovel dump service to blow off the auxiliary relief valve.

2

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

3

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

B

located on the pump pressure out line.

4

Start the engine and run at 2200 rev/min.

5

Raise the loader arms to achieve full travel, hold the arms in this position and note the gauge reading, which should be as specified in

Technical Data

.

6

If the pressure is higher than specified, the pressure compensator spool may be set incorrectly or the swashplate may not be moving.

If the pump pressure is lower than specified, the flow spool may be set incorrectly, or there may be a leak in the load sense line.

Do not make any adjustments at this stage. Complete the other checks detailed in this section.

7

Refer to R

egulator Valve Adjustment

.

D

C

B

E

F

9803/3280

Purchased from www.WorkshopManuals.co.uk

S315770

Issue 1

Section E

22 — 4

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 4

Variable Flow Pumps

Flow and Pressure Testing (Cont’d)

Pump Flow

It is not possible to test full pump flow at system pressure whilst the pump is installed on the machine. This is because the pump swashplate angle will return to minimum angle

(zero flow) when the system reaches full pressure (see descriptions).

However, it is possible to test the pump flow whilst ‘blowing off’ an auxiliary relief valve which is set lower than system pressure. In the example below, the shovel head side A.R.V.

is used. The readings taken in this test give a ‘snapshot’ of pump performance and can be used to establish if major pump maintenance is required.

1

Warm the hydraulic oil to working temperature, i.e. 50°C

(122°F):

a

Set the engine speed to 2200 rev/min.

b

Operate the loader shovel dump service to blow off the auxiliary relief valve.

2

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

3

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

B

located on the pump pressure out line.

4

Connect a flowmeter to the pump pressure out line as shown at

C

.

5

Start the engine and run at 2200 rev/min.

6

Raise the loader arms and fully dump the loader shovel.

7

Hold the shovel in the dump position (to blow off the

A.R.V.) and c hec k t he f lo w and p ressure g aug e readings, which should be as specified in

Technical

Data

.

8

If the pump flow is not as indicated, do not make any adjustments at this stage. Complete the other checks detailed in this section.

9

Refer to

Regulator Valve Adjustment

.

Load Sense Line Flow

The load sense line c ommunic at es t he load p ressure required at a service to the pump. If there is a blockage or leak in the line, the hydraulic system will not operate effectively.

Load sensing is a ‘dynamic flow’ type. That is, there is a constant flow of oil from the pump to the shuttle valves.

When a pressure signal is felt at the service port, the flow is interrupted and the pump immediately responds to the demand. (Unlike a ‘static’ system where the pressure signal must move from the valve block, back up the load sense line to the pump).

1

Warm the hydraulic oil to working temperature, i.e.

50°C (122°F):

a

Set the engine speed to 2200 rev/min.

b

Operate the loader shovel dump service to blow off the auxiliary relief valve.

2

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

3

Connect a flowmeter into the load sense line, a good access point is where the LS line enters the backhoe valve as shown at

D

.

5

Start the engine and run at 2200 rev/min. Check the flow which should be as specified in

Technical Data

.

6

If a service is selected, the flow should drop to zero

(but the pressure will increase).

7

If there is no flow in the system, then check the load sense lines for being trapped or kinked, also move the service control levers and the steering wheel.

If there is still no flow, then there is the possibility of a shuttle valve being stuck. Do not dismantle valves at this stage but complete all other tests listed in this section.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

22 — 5

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 5

Variable Flow Pumps

Regulator Valve Adjustment

Note:

If a new regulator valve is fitted, or a valve stripped, cleaned and rebuilt, then the pressure spool should be backed off to a low pressure. This will prevent inadvertent damage to the pump.

Flow Regulator Spool

The pressure in the pump out line (pressure test connector

B

) should be 20 bar (290 lbf/in

2

) greater than the pressure in the load sense line (pressure test connector

A

). If not adjust the regulator flow spool as described below:

1

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

2

Gain access to the regulator valve assembly (mounted on the pump).

3

Remove cap

C

and loosen locknut

D

.

4

Turn adjusting screw

E

clockwise to increase pressure setting and anti-clockwise to decrease setting.

5

Rep eat p ressure t est as d et ailed p reviously and establish valve is set correctly.

6

Tighten locknut, refit cap.

Pressure Regulator Spool

As previously explained, there is no ‘main relief valve’ to control the system pressure (the pump swashplate angle will increase or decrease according to pressure demand).

However in situations of maximum hydraulic stall, i.e. ram full travel, the pressure in the circuit will achieve the setting of the pressure regulator spool. To adjust the setting:

1

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

2

Gain access to the regulator valve assembly (mounted on the pump).

3

Remove cap

F

and loosen locknut

G

.

4

Turn adjusting screw

H

clockwise to increase pressure setting and anti-clockwise to decrease setting.

5

Rep eat p ressure t est as d et ailed p reviously and establish valve is set correctly.

6

Tighten locknut, refit cap.

F C

G

D

H E

A

B

9803/3280

S273401

S273100

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

22 — 6

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 6

Variable Flow Pumps

Regulator Valve Adjustment (Cont’d)

The load sense system is a dynamic type, which means a small flow (0.22 t o 1.1 gall/ 1 t o 5 lit re p er minut e) is circulated through the load sense line.

The flow is available due to a 0.02 in (0.6 mm) orifice in the flow regulator spool in the pump control housing. This orifice can be blocked or partially restricted which will give poor performance, slow operating speed and/or low maximum stall speed. If completely blocked, margin pressure and stand-by pressure can be difficult to adjust and the loader servic es may op erat e int ermit t ent ly even t hough t he excavator operates correctly.

If any of the above symptoms are experienced carry out the following:

1

Lower the backhoe bucket and loader shovel to rest on the ground. Stop the engine and remove the starter key.

2

Gain access to the regulator valve assembly.

3

4

5

6

7

Disconnect the load sense line at

A

. Attach a 0.25

inch (6.35 mm) hose to pump of suitable length to route to a measuring container.

Start the engine and measure the flow which should be at least 0.22 gall/1 litre per minute at 2200 RPM.

If the flow is below 0.22gall/1 litre per minute, remove spool

B

and clean/unblock orifice

C

as required.

Fit spool

B

and check the flow as described at step 3 and 4.

If the flow is within limits check the stand-by pressure.

Refer to

Flow and Pressure Testing

.

B

C

B

9803/3280

A

Purchased from www.WorkshopManuals.co.uk

347850

Issue 1

Section E

22 — 7

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 7

Variable Flow Pumps

Renewing Drive Shaft Seal

Note:

The following procedure describes renewal of the shaft seal. However this is not the normal sequence, the sealing ring would normally be assembled with the taper roller bearing from inside the pump to ensure a secure sealing condition. If the shaft seal is to be renewed in this manner, it is extremely important not to scratch or damage the shaft, otherwise leakage will occur.

1

Remove retaining ring

1

and use a special rounded tool such as a ground screwdriver to remove the drive shaft sealing ring

2

.

2

Examine the seal running area (driveshaft and housing) for wear or damage. Damage in these areas will require the pump to be further dismantled.

3

Lubricate the new seal with JCB Special MPL Moly

Grease.

4

Install the new seal, it is advisable to use a tube or similar located over the driveshaft to ensure the seal enters the housing evenly. DO NOT push the seal too far into the housing. If the shaft seal touches the bearing, the seal will be damaged.

5

Assemble the retaining ring

1

.

1

2

S271880

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

22 — 8

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

22 — 8

Variable Flow Pumps

Shuttle Valve Signal Network — Testing

The shuttle network can be easily checked. Start the engine and operate the hydraulic system until the oil is at working temperature.

With the engine at 1500 revs/min operate each service in the following order:

1 Bucket

2 Dipper

3 Right Stabiliser

4 Left Stabiliser

5 Boom

6 Slew

7 Extradig

8 Lift

9 Shovel

10 Auxiliary

11 Steering

Note

: If your machine is not equipped with these valve sections, start with the furthest section from the pump and work back to the nearest section.

If one valve section function either fails to work or is slow to work in either one or both directions, the primary shuttle in that section may be at fault.

If two or more valve sections next to each other fail to operate correctly, check the secondary shuttles. To check the secondary shuttle operate each service in sequence, the last correctly functioning service nearest the pump may have a secondary shuttle in that section at fault.

When a shuttle is suspected of malfunctioning, do the following check:

Stall any control valve that is near the pump than the suspected control valve. This should stall the entire system.

While at stall operate the malfunctioning valve section, if the section operates correctly the shuttle in question is at fault.

If section still malfunctions the shuttle is NOT at fault.

Shuttles may be removed, check the seals and the shuttle ball. Clean and refit or fit a new shuttle as required.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

23 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 1

Loader Valve — Pressure Testing

Main Relief Valve (M.R.V.)

Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

1

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

A

on the loader valve, (refer to

Service Tools

).

2

With the engine running at 1500 revs/min, check M.R.V.

pressure by raising or lowering the loader arms until the rams are fully open or closed and noting the maximum gauge reading.

CAUTION

: Do not select ‘ float’ . The maximum pressure should be as stated in Technical

Data.

Note:

The rams must be ‘held’ open or closed when reading gauge.

3

If the pressure is incorrect, loosen locknut

D

and adjust screw

C

. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required.

A

352710

D

C

9803/3280

A

Purchased from www.WorkshopManuals.co.uk

S266281

Issue 1

Section E

23 — 2

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 2

Loader Valve — Pressure Testing

Unloader Valve

Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

Make sure that the ‘hydraulic speed control’ and ‘smooth ride system’ facilities are NOT switched on, otherwise the correct unloader valve pressure cannot be obtained.

If the machine has a front-mounted roadbreaker, ensure that the roadbreaker control valve lever is in the ‘ off’ position

(lever down), otherwise the roadbreaker relief valve will operate and prevent unloader valve pressure from being reached.

1

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

A

.

2

With the engine running at 1500 revs/min, slowly operate arms raise or lower.

Note 1:

The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.). Selecting this service ensures that the pressure vents through the M.R.V. and not an A.R.V.

3

When the service reaches full travel, return the lever to the neutral position. Select the service again, very slowly, the pressure gauge will rise until a step/kick is seen in the rate of change in the pressure increase. This is the start of unloader operation. Keep selecting the service until a sudden sharp increase in pressure is observed with a change of engine sound, this point is the unloader setting and should be as specified in

Technical Data

.

4

If the pressure is incorrect, slacken locknut

E

and adjust cap

F

. Turn it clockwise to increase pressure and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required.

If the correct pressure cannot be achieved, add or subtract shims as required, refer to

Loader Valve —

Fixed Flow, Dismantling and Assembly — Unloader

Valve

.

A

F

E

352710

A

S266300

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

23 — 3

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 3

Loader Valve — Pressure Testing

Hydraulic Speed Control (HSC)

The following procedure can be used to establish if the hydraulic speed control facility is working correctly.

Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

1

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

A

.

2

With the engine running at 1500 revs/min, slowly operate arms raise, the pressure should be approximately 138 bar (2000 lbf/in

2

).

3

Make sure that the HSC rocker switch (mounted on the console) is in the OFF position. Raise the arms slowly, select the rocker switch to ON, the arms should raise quicker.

4

Make sure that the HSC rocker switch (mounted on the console) is in the OFF position. Raise the arms slowly, press the button on the loader control knob, the arms should raise quicker.

5

If the loader arms fail to respond, then check the HSC hydraulic and electrical circuits for any faults.

A

352710

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

23 — 5

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 5

Loader Valve — Pressure Testing

Auxiliary Relief Valves — Using Hand Pump

To pressure test and re-set the auxiliary relief valves

(A.R.V.’s), service kit 892/00309 must be used.

The service kit comprises; a test block

1

, a setting body

2

with adjusting pin

3

, a special spanner

4

, anti-cavitation lock out bung

5

. A.R.V. cartridge removal tool 892/00335 comprises; an extractor cap

6

and a ‘C’ washer

7

.

1

4

6

7

2

1

Remove the complete A.R.V. assembly from the valve block. If the A.R.V. sub-assembly

7

remains in the valve block, proceed as follows:

a

Fit extractor cap

11

over the A.R.V. sub-assembly

7

, into the valve block

E

.

b c

Fit ‘C’ washer

12

on top of the extractor cap, but under the anti-cavitation spring seat as shown.

Unscrew the extractor cap, — the A.R.V. subassembly will withdraw with the extractor cap.

5

3

S196700

E

! @

7

S162560

2

Use special spanner

4

located in cross holes

A

and separate the A.R.V. sub-assembly

7

from its cap

8

.

A

4

7

S162570B

8

3

Install adjusting pin

3

into setting body

2

.

2

3

S162570C

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

23 — 6

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 6

Auxiliary Relief Valves — Using Hand Pump

4

Install the A.R.V. sub-assembly into setting body

2

.

Make sure that the adjusting pin

3

correctly locates in adjusting screw

9

.

Make sure that the lock nut

10

correctly locates in the setting body socket — the anti-cavitation cone should still be closed, as shown at

B

.

0

3

9

2

B

S162570D

5

Install the A.R.V. sub-assembly and setting body into test block

1

. Make sure that the assembly is installed in the port marked ‘

RV

‘ (relief valve).

1

6

Connect a hydraulic hand pump to port ‘

P

‘ (pump) of the test block

1

. Make sure that the hand pump is filled with JCB Hydraulic fluid.

Connect a 0 to 400 bar (0 to 6000 lbf/in

2

) pressure test gauge to port ‘G’ (gauge) of the test block

1

.

Port ‘

T

‘ (tank) can be left open when using a hydraulic hand pump.

7

Raise the pressure at the valve inlet using the hydraulic hand pump, when the A.R.V. ‘cracks’ and oil escapes from the port marked ‘

T

‘ the pressure gauge will indicate the A.R.V. setting.

If the A.R.V. setting is correct, move to step 12.

If the A.R.V. setting is not correct, move to step 8.

S162570F

S162570F

9803/3280

Purchased from www.WorkshopManuals.co.uk

1

S162570E

Issue 1

Section E

23 — 7

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 7

Auxiliary Relief Valves — Using Hand Pump

8

Use the hand pump to raise approximately 172 bar

(2500 lbf/in

2

) pressure at the valve inlet.

Note:

Raising the pressure at the valve inlet locks the anticavitation cone

C

onto its seat, this allows the A.R.V.

adjusting screw lock nut

10

to be loosened (step 10).

If the pressure is maintained move to step 10.

If the pressure falls off rapidly, or if no pressure can be obtained it is possible that the anti-cavitation cone is not seating effectively, in this instance move to step 9.

C

0

S162570G

9

If no pressure can be raised (see step at the valve inlet, remove the A.R.V. assembly and install anticavitation lock-out bung

6

in the port marked ‘

RV

‘ , make sure that the bung O-ring face seal

D

is facing out. Re-fit the A.R.V. assembly.

Note:

The anti-cavitation lock-out bung seals and locks the

A.R.V. anti-cavitation function. The bung is only suitable for the test block application and must NEVER be fitted to the valve block.

The bung can be extracted using a 3/8 — 16 UNC threaded bolt.

D

6

S162570H

10

Release the A.R.V. adjusting screw lock nut (see note):

Engage the nut at the end of setting body

2

using the slot in special spanner

4

, turn the nut anti-clockwise to release the A.R.V. adjusting screw lock nut.

Note:

Remember, it will not be possible to release the lock nut if there is not approximately 172 bar (2500 lbf/in

2

) pressure at the valve inlet.

4

2

S162570J

11

Insert an allen key into adjusting pin

3

(T-Bar type shown). Push the adjusting pin down and make sure it has engaged with the A.R.V. adjusting screw.

Rotate the T-bar clockwise to increase the pressure setting and anti-clockwise to decrease the pressure setting.

After adjustment, use the slot in spanner 4 to lock the

A.R.V. adjusting screw lock nut (see note).

Note:

Remember, pressure must be maintained at the valve inlet to ensure the lock nut is tightened.

4

3

S162570K

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

23 — 8

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 8

Auxiliary Relief Valves — Using Hand Pump

12

When the correct A.R.V. setting has been attained, release the pressure in the test block. Remove the

A.R.V. sub-assembly and its setting body from the test block.

Separate the A.R.V. sub-assembly from its setting body.

Install the A.R.V. sub-assembly into its cap.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

www.WorkshopManuals.co.uk

Hydraulics

23 — 9 Service Procedures

Excavator Valve — Pressure Testing

Auxiliary Relief Valves — Using Hand Pump

The auxiliary relief valves found in the backhoe valve block are identical in design to those found in the loader valve block.

Therefore please refer to

Loader Valve — Pressure Testing,

Auxiliary Relief Valves (ARV’s)

for the correct pressure test procedures.

To p ressure t est and re- set t he auxiliary relief valves

(A.R.V.’s), service kit 892/00309 must be used.

The service kit comprises; a test block

1

, a setting body

2

with adjusting pin

3

, a special spanner

4

, anti-cavitation lock out b ung

5

. A.R.V. c art rid ge removal t ool 892/ 00335 comprises; an extractor cap

6

and a ‘C’ washer

7

.

1

4

6

5

Section E

23 — 9

7

2

3

S196700

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

23 — 10

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 10

Excavator Valve — Precision Control (Servo)

*

(Machines up to serial no. 931159)

Pressure Testing

Load Sense Drain Regulator and Relief Valve

Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control levers to vent residual hydraulic pressure.

1

Connect a 0 — 400 bar (0 — 6000 lbf/in

2

) pressure gauge to pressure test connector

A

on the loader valve, (refer to

Service Tools

).

2

With the engine running at 1500 revs/min, check that the M.R.V. pressure is correct, see

Loader Valve —

Pressure Testing, Main Relief Valve.

3

With the engine running at 1500 revs/min, operate a stabiliser service fully and at the same time note the reading in the gauge which should be as stated in

Technical Data

.

Note:

The ram must be ‘held’ open or closed when reading gauge.

4

If the pressure is incorrect, loosen locknut

D

and adjust screw

C

. Turn the screw

C

clockwise to increase pressure and anti-clockwise to decrease the pressure.

When the pressure is correct, tighten the locknut and check the pressure again. Adjust as required.

A

C

D

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402500

Issue 2*

Section E

23 — 11

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 11

Excavator Valve — Precision Control (Servo)

(Machines from January 2003)

Pressure Testing

Load Sense Relief Valve

TBA

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

23 — 12

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

23 — 12

Excavator Valve — Precision Control (Servo)

Pressure Compensator Network — Testing

The pressure compensator valve network can be easily checked as follows:

1

Start the engine and operate the hydraulic system until the oil is at working temperature.

2

With the engine at 1500 revs/min operate each service in turn starting with the service furthest from the pump inlet section.

If one control valve section function either fails to work or is slow to work in either one or both directions, the pressure compensator valve in that section may be at fault.

When a pressure compensator valve is suspected of malfunctioning, do the following check:

3

Stall any control valve that is nearer the pump inlet section than the suspected control valve section. This should stall the entire system. While at stall operate the malfunctioning valve section, if the section operates correctly the pressure compensator valve in question is at fault.

If the section still malfunctions the pressure compensator valve is NOT at fault.

Note:

The pressure compensator valves may be removed for inspection, refer to

Excavator Valve — Dismantling and

Assembly

. Clean and refit, or fit a new pressure compensator valve as required.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

24 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

24 — 1

Ram Creep Tests — All Services

If ram creep is suspected the following procedures must be carried out to define if the leakage is within tolerance. Ram c reep c an b e c aused b y a num b er o f reaso ns:

Cylinder/Piston Leakage, Spool Leakage, ARV Leakage.

The text and illustrations show a typical ram installation (in this instance the boom ram), the principle applies to all rams.

Note:

The procedures are not applicable for rams fitted with hose burst protection valves.

!

WARNING

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

!

WARNING

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

TRANS 1-2

A Test for Ram Creep

1

Operate the machine to bring the hydraulic oil to a normal working temperature of 50°C (122°F) which can be measured using a hydraulic oil temperature probe

(service tool 892/00285).

2

Fit an appropriate pressure gauge

A

to a tee-piece in the service hose which is pressurised when the ram in question is supported (Fig 1).

3

Operate the rams to ensure they are full of hot oil.

4

Apply a load to the suspect ram for example the boom ram by raising the dipper to the horizontal as at

B

.

5

M easure t he ac t ual p ist on rod movement over 10 minutes. Measure the movement by checking the pivot pin to pivot pin dimensions as at

C

. Alternatively mark the rod with a felt tip pen 150mm (5.9 in) from the end cap and check the movement after 10 minutes, this is not possible on the majority of boom/extending dipper rams.

6

Using Table 1, check if the piston rod movement is within the recommended tolerance. If so, the ram creep is acceptable.

Note:

The table indicates the MAXIMUM permitted ram movement.

7

If the rate of movement is unacceptable, identify if the fault is as a result of cylinder/piston leakage or spool leakage at the control valve, see procedure

B

and

C

.

A

C

B

C

9803/3280

FIG 1

380190

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

24 — 2

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

24 — 2

B Test Cylinder/Piston Leakage

1

Ensure that the oil temperature is at 50°C (122°F) by using the hydraulic oil temperature probe detailed in A1.

2

Take the weight off the ram to be tested, in this example, by positioning the backhoe with dipper vertical and bucket on the ground.

3

Use a suitable pressure gauge

A

to blank off the supporting port of the ram.

4

Disconnect the hose from the opposite port

D

and leave the port open to atmosphere.

5

Apply a load to the suspect ram for example the boom ram by raising the dipper to the horizontal as at

B

.

6

After the initial movement measure the pin to pin movement as at

C

and note the rod movement over 10 minutes.

7

If rod movement is evident the ram is defective.

C Test Spool Leakage

Note:

The following procedure applies only to services fitted with A.R.V.’ s. Note A.R.V.’ s are not fitted to loader lift, loader auxiliary, stabilisers or to the bucket rod side service except when a Rockbreaker is fitted.

1

Render the A.R.V.’s inoperative in the suspect service.

This is achieved by removing the A.R.V. and replacing with a blanking plug (part no. 25/609901) and seal kit

(25/610301).

2

Re-check the piston rod movement as described steps

A1 to A6.

D

A

C

A.R.V.

Control Layout

JCB ISO

Slew

— Right

— Left

Boom

— Rod

— Head

Dipper

— Rod

— Head

Bucket

— Rod

— Head

B1

A1

B2

A2

A5

B5

A6

B6

B1

A1

B5

A5

A2

B2

A6

B6

Note:

Bucket ram rod side ARV only fitted to machines equipped with Rockbreakers.

B

C

3

If the rod movement is now acceptable the A.R.V. must be at fault. The A.R.V. may only require cleaning and then resealing. If dirt is evident, the hydraulic tank should be drained and cleaned. It is recommended that when re-filling the hydraulic tank that new oil and filter be used to prevent further contamination. If the A.R.V. is worn it should be replaced.

FIG 2

9803/3280

Purchased from www.WorkshopManuals.co.uk

A401470

Issue 1

Section E

24 — 3

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

24 — 3

Table 1

Ram Cylinder

Dia. (mm)

Rod

Dia. (mm)

Total Displacement — mm/10 minutes @

69 bar

(1000 lb/in

2

)

138 bar

(2000 lb/in

2

)

207 bar

(3000 lb/in

2

)

HEAD SIDE

Backhoe

S/shift Jack Leg

Knuckle

Ext Dip

Loader

Clam

Lift

Lift

ROD SIDE

Backhoe

Boom

Boom

Boom

Boom

Bucket

Bucket

Dipper

Dipper

Ext Dip

70

100

70

70

80

90

40

60

40

40

50

50

13

6

13

6

5

4

44

16

32

22

17

13

91

32

65

45

35

28

110

120

130

140

90

100

100

110

70

50

60

60

65

40

60

65

70

75

11

10

10

8

19

5

5

8

6

45

40

34

28

66

26

22

19

16

52

44

37

32

114

99

70

57

96

Loader

Shovel 70 40 10 33 68

Using the figures above, a graph can be plotted and the maximum amount of movement determined. See the next page for a working example.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

24 — 4

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

24 — 4

EXAMPLE —

Boom Ram110 x 60

1

Using the figures given in the table on page 3, plot a graph for the ram to be tested.

2

Check the pressure in the ram (induced by the applied load). In this example the pressure on the gauge reads

107 bar; 1500 lb/in 2 .

3

Draw a vertical line from the pressure reading to the plotted graph line. Where the vertical line intercepts the graph line, draw a horizontal line and read the permitted ram d isp lac ement . In t his examp le t he p ermit t ed maximum displacement is 18 mm.

N ot e

: A b lank g rap h is p ro vid ed o n t he nex t p ag e, photocopy and use as required.

120

100

80

9803/3280

60

52mm

10:60

40

Boom Ram 1

26mm

20

18mm

8mm

0

50

69bar

100

107bar

150

138bar

PRESSURE (BAR)

200

207bar

250

380210

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

24 — 5

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

24 — 5

120

100

80

60

40

20

0

50 100 150

PRESSURE (BAR)

200 250

380220

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

25 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

25 — 1

Quick Release Couplings

— Connecting and Disconnecting

Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently.

Generally, your machine pipework will have female couplings

A

fitted, and the optional attachment hoses will have male couplings

B

fitted.

The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings.

Finally, p lease read t he c orrec t fit t ing and releasing procedures before installing or removing any optional attachment fitted with quick release couplings.

Quick Release Couplings — Do’s & Don’ts

DO

wipe the two faces of the coupling and make sure they are clean before connecting.

DO

make sure the outside sleeve (female coupling) is pulled back when disconnecting.

DO

connect and disconnect a new coupling two or three times to ‘work’ the PTFE seals — sometimes a new coupling will stick if the seals have not been ‘worked’.

DO

use a spanner on the hexagon flats of the coupling when fitting adaptors.

DO

use a rubber or hide hammer to disconnect a coupling if it sticks — sticking may occur if there is dirt present in the coupling.

DON’T

attempt to re-connect a damaged half coupling — this will destroy the seals and necessitate replacing both half couplings.

DON’T

leave the coupling where it may be run over by a machine or otherwise crushed — this will distort the coupling sleeve and prevent correct connection and disconnection.

DON’T

clamp on the smooth diameter of the coupling when fitting adaptors — always use the hexagon.

DON’T

try to turn the sleeve (female coupling) when the coupling has been disconnected — the locking ball will wedge underneath the sleeve and destroy the coupling.

DON’T

damage the faces of the couplings — this can prevent connection and disconnection, or damage seals and cause leakage.

DON’ T

t ry t o d ismant le t he c oup lings — t hey are non serviceable parts. If a coupling is damaged it should be replaced with a new one.

!

WARNING

Hydraulic fluid at pressure can injure you. M ake the machine safe before connecting or disconnecting quick release couplings; stop the engine and then operate the attachment control a few times to vent residual hydraulic pressure in the attachment hoses.

2-4-1-11

Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. This is usually achieved by switching off the engine and then operating the attachment control lever several times. Make sure the hose service line has been vented b ef o re c o nnec t ing o r rem o ving ho ses — ref er t o t he appropriate attachment information in this section.

Connecting Quick Release Couplings

1

Remove any residual hydraulic pressure trapped in the service line hose.

2

Wipe the two faces of the male and female couplings and make sure they are clean.

3

Make sure that ball

C

in the female coupling is located in one of its slots.

4

Fit the male coupling into the female coupling; To ensure that the coupling is not accidentally released, rotate sleeve

E

half a turn and make sure that the locking ball

C

does not align with the slot

D

.

Disconnecting Quick Release Couplings

1

Remove any residual hydraulic pressure trapped in the service line hose.

2

Align the slot

D

with ball

C

.

3

Pull back sleeve

E

to release the coupling.

A

B

C

E

D

S169490

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

26 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

26 — 1

Smooth Ride System

Charging/Discharging the Accumulator

Charging

1

Park the machine on level ground, lower the loader arms, switch off the engine and chock all four wheels.

Release all hydraulic pressure in the accumulator by selecting the starter key to the ON position without the engine running, SRS ON and operating the loader arm hydraulic lever.

2

Remove gas valve guard

A

and gas valve cap

B

.

3

Screw T handle

C

all the way out (counter clockwise) before attaching charging tool (service tool 892/00948) to accumulator gas valve.

4

Close bleed valve

D

.

5

Making sure not to loop or twist the hose, connect the charging tool to the gas valve. Tighten to 1.0 lbf ft (1.36

Nm, 0.14 kgf m).

6

Connect charging tool to a bottle of compressed nitrogen gas.

7

Screw T handle

C

all the way in (clockwise), this will depress the core in the gas valve. Check charge pressure which should be set to suit the loader and the attachment fitted to the machine. For recommended charge pressures refer to

Technical Data — Smooth

Ride System

.

8

If charge pressure is low, carefully open hand valve

E

on the nitrogen bottle and SLOWLY fill the accumulator.

Close valve

E

when the required charge pressure is reached on the gauge.

9

Let the pressure settle for 10 to 15 minutes. This will allow the gas temperature to stabilise. If the charge pressure is exceeded, with the gas bottle closed, open bleed valve

D.

Reduce pressure as required, then close bleed valve.

!

CAUTION

To reduce pressure use the recommended charging tool or the charge valve could be damaged which may result in rapid discharge of the accumulator.

HYD 2-4

10

When complete screw T handle

C

all the way out

(counter clockwise) then open the bled valve

D

to vent the hose.

11

Hold the gas valve to keep from turning, loosen nut and remove charging tool.

12

Refit gas valve cap and valve guard.

Discharging

1

Park the machine on level ground, lower the loader arms, switch off the engine and chock all four wheels.

Release all hydraulic pressure in the accumulator by selecting the starter key to the ON position without the engine running, SRS ON and operating the loader arm hydraulic lever.

2

Remove gas valve guard

A

and gas valve cap

B

.

3

Screw T handle

C

all the way out (counter clockwise) before attaching charging tool (service tool 892/00948) to accumulator gas valve.

4

Close bleed valve

D

.

5

Either connect charging tool to a bottle of compressed nitrogen gas which is turned off or remove hose

F

and fit a suitable blank on charging tool.

6

Screw T handle

C

all the way in (clockwise), this will depress the core in the gas valve.

7

Open bleed valve

D

until all the gas charge is relieved from the accumulator. Remove the charging tool.

A

F

B

C

D

E

S308270

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

27 — 1

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

27 — 1

Hose Burst Protection Valves

The hose burst protection valves (if fitted) prevent the loader or backhoe falling in the event of a hose burst. These valves may be fitted on rams which raise or lower the loader arms, the boom or the dipper.

Checking

1

Raise the loader arms fully. Raise the boom to about

45°. Raise the dipper to the horizontal.

2

Stop the engine

3

Using the control levers, try to lower the loader, boom and dipper. Push the levers fully to the ‘lower’ position.

If there is any movement, adjust or replace the hose burst protection valve as applicable.

Lowering a Load — In a Failure Condition

During normal operation, the engine must be running before a load can be lowered. The following paragraphs describe how to safely and correctly lower a load in the event of engine failure or a hose burst; we recommend that only a competent maintenance engineer perform the procedures.

After lowering a load do not use the machine until the manual over-ride screw has been reset (Loader HBPV, refer to

Pressure Testing — Loader Lift Ram

) or a new end cap and valve assembly fitted (Boom HBPV, refer to

Hose Burst

Protection Valves — Dismantling and Assembly

), otherwise the valve will not operate as intended.

S320930

A

A171340

B

C

D

S170582

!

DANGER

Do not stand underneath the raised load during the lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load. If you do not follow these precautions you or others could be killed or seriously injured.

2-3-5-3

Boom and Dipper Hose Burst Protection Valve (HBPV)

1

Remove cap

A

and pierce the warning label.

2

If a hose has burst, position a suitable container to catch the oil.

3

Insert an 6mm allen key into the socket head of screw

B.

Slowly turn the allen key in a clockwise direction until the load just begins move.

Burst hose

—

Lower the boom using screw

B

, turn the screw counter-clockwise to slow or stop the load from lowering.

Dead engine

—

Operate the control lever in the cab to lower the load.

Loader Hose Burst Protection Valve (HBPV)

1

Remove cap

C

from both HCPV check valves on the loader lift arms.

2

If a hose has burst, position a suitable container to catch the oil.

3

On the burst hose HBPV, insert an 5mm allen key into the socket head of screw

D.

Turn the allen key in a clockwise direction so that the screw winds fully in.

Repeat slowly for the opposite side as the load is now supported on this HBPV.

Note

: Count the number of full turns on each screw for resetting purposes.

4

Operate the control lever in the cab to lower the load.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

27 — 2

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

27 — 2

Hose Burst Protection Valves

Pressure Testing — Loader Lift Ram

The following text describes the pilot valve setting procedures and pressure testing sequences for ONE HBPV only, repeat the procedures for BOTH loader arm lift rams.

Preparation

Before starting the pressure testing procedure vent hydraulic system pressure as follows:

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

2

Lower the loader arms to the ground (not lifting the machine).

3

Select ‘ ARMS LOWER’ to raise the front wheels approximately 25 — 50 mm (1 — 2 in) off the ground.

4

Switch off the engine.

5

Make sure all personnel are clear of the machine before completing step 6.

6

Select ‘ARMS RAISE’ — this will vent residual hydraulic pressure from the loader rams (head side).

7

Move all the backhoe control levers back and forth to vent any other residual hydraulic pressure from the backhoe service hoses.

Pilot Valve Setting Procedure

The pilot valve assembly, shown at

C

, must be set correctly before doing the relief valve pressure test. If the pilot valve is screwed too far into the HBPV it will create a flow path connection from port C2 to port V2 (see descriptions of operation).

To set the pilot valve assembly:

1

Remove pilot housing, item

D

, from the HBPV.

2

Check that the end face of the pilot valve assembly, item

C

, is flush (level) with the end face of its housing

D

, as shown at

E

.

3

If necessary, remove end cap

F

and, using a suitable

Allen key, adjust the pilot valve as required.

4

Refit the end cap.

Continured…………

J

K

A

B

E

G

C

D

F

327330

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

27 — 3

www.WorkshopManuals.co.uk

Hydraulics

Service Procedures

Section E

27 — 3

Hose Burst Protection Valves

Pressure Testing — Loader Lift Ram

(continued)

Relief Valve Pressure Test

If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test procedure is described in steps 2 to 6.

1

Pre-set the relief valve:

a

Remove cap

B

and its copper washer. Using an

Allen key, turn the adjusting screw anti-clockwise to remove all tension.

b

Using your fingers, turn the adjusting screw clockwise until a soft force (resistance) is felt.

c

Using an Allen key, turn the adjusting screw a further 21/4 turns to pre-set the relief valve. Refit the cap and washer.

2

Remove hose

G

from port C2. Cap and plug the hose and valve port adapter (the valve port adapter MUST be plugged, otherwise the test procedure will not work).

3

Remove hose

J

from port V2. Plug the hose but DO

NOT cap the valve port adapter.

4

Remove plug

A

and in its place fit a 0-400 bar (0-6000 lbf/in 2 ) pressure gauge connected to a hand pump.

5

Use the hand pump to increase the pressure. When the pressure reaches the setting of the relief valve, oil will escape from port V2, shown at

K

. Note the maximum gauge reading (the setting of the hose burst relief valve) which should be 250 bar (3625 lbf/in 2 ).

6

If necessary, adjust the pressure setting as follows:

a

Remove cap

B

and its copper washer.

b

Using an Allen key, turn the adjusting screw clockwise to increase the pressure or anticlockwise to decrease the pressure. For information; one full turn of the relief valve adjusting screw is equivalent to approximately 110 bar (1595 lbf/in 2 ).

c

Replace the cap and washer.

d

Repeat pressure test, adjust as necessary.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

30 — 1

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

30 — 1

Fixed Flow

Removal and Replacement

The following Procedure describes removal and replacement of a double section pump, follow the same procedure for single section pumps.

Removal

!

WARNING

Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the parking brake, remove the starter key, disconnect the battery.

INT-3-3-8

1

Remove the propshaft, refer to Section F

Propshafts —

Removal and Replacement

.

2

Drain the hydraulic fluid from the hydraulic tank.

3

Remove flange bolts

B

(4 off) and disconnect the pump inlet hose flange from the pump body. Blank off all exposed connections to prevent ingress of dirt.

4

Disconnect the pump outlet hoses

C

and

D

from the elbow fittings. Blank off all exposed connections to prevent ingress of dirt.

!

CAUTION

The hydraulic pump is heavy. Do not attempt to remove the pump unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3

5

Secure the pump using a sling around the pump body, remove t he p ump mount ing b olt s

E

and c arefully withdraw the pump clear of the gearbox.

Replacement

Replacement is the reverse of the removal procedure.

1

Clean off all traces of gasket compound from the pump and gearbox mounting faces. Apply a thin bead of JCB

Multigasket to the gearbox mounting face.

2

Locate the splined shaft of the pump into the gearbox.

Apply JCB Threadlocker and Sealer to bolts

E

and secure the pump flange to the gearbox mounting face.

3

Reconnect the pump outlet hoses

C

and

D

to the elbow fittings.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant JCB

Threadseal applied to the threads of the adapter.

4

Reconnect the pump inlet hose flange to the pump body with bolts

B

(4 off).

5

Fit the propshaft, refer to Section F

Propshafts —

Removal and Replacement

.

6

Fill the system to the correct level with recommended hydraulic fluid, refer to Section 3

Fluids, Lubricants,

Capacities and Specifications

.

Note:

Replace the suction strainer and return line filter after fitting a new or serviced pump.

7

After fitting a new or serviced pump and before starting the engine screw the main relief valve out. Run the engine and check for leaks, also check the main relief valve (M.R.V.) operating pressure. Refer to Section E

Service Procedures, Pressure Testing — MRV

.

Torque Settings

Item Nm kgf m lbf ft

B

E

TBA

TBA

C

D

E

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

A396190

Issue 1

Section E

31 — 1

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

31 — 1

S401450

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

31 — 2

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

31 — 2

Fixed Flow

Dismantling and Assembly

Before removing and dismantling the pump, check flow and pressure. If either of these are low the pump must be changed. Renewal of components such as gears, bearings and housing will not effect a permanent cure. If the pump output is satisfactory but there is external leakage, the pump should be removed and dismantled for re-sealing only.

Before removing and dismantling the pump, make sure the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination.

Dismantling

1

Remove the four bolts

3

and serrated washers

4

which clamp the units together.

2

Use a soft faced hammer to separate front body

5

and rear body

6

after first marking them to ensure correct re-assembly.

3

Remove splined coupling

7

and O-rings

8

. Discard the

O-rings.

4

Use a soft faced hammer to separate end cover

9

from rear body

6

, after first marking them to ensure correct re-assembly.

5

Remove drive gear

10

from its bore. Pushing it out of t he rear b od y w ill also rem ove b alanc e p lat e

11

complete with seal

12

and seal energiser

13

. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.

6

Remove driven gear

14,

followed by balance plate

15

complete with seal

16

and seal energiser

17

. Discard the seal and seal energiser.

7

Discard O-ring

18.

8

Use a soft hammer to separate mounting flange

19

from front body

5

, after first marking them to ensure correct re-assembly.

9

Remove circlip

21

and shaft seals

22.

Note which way round the seal lips are fitted to ensure correct fitting of new seals on re-assembly.

10

Remove driveshaft

23

from front body

5

. Removal will also remove balance plate

28

complete with seal

29

and seal energiser

30

. Discard the seal and seal energiser.

11

Remove driven gear

27

followed by balance plate

24

, seal

25

and seal energiser

26.

Discard the seal and seal energiser.

12

Discard O-ring

31

.

13

Remove all sealant from the contact faces of the mounting flange/front body and end cover/rear body interfaces.

14

Wash all components and immediately apply a coating of hydraulic oil to prevent corrosion.

Inspection

1

Generally check all pump parts for damage and/or wear. The O- ring grooves, the seal recess in the mounting flange and all sealing faces must be free of burrs and scores which could result in seal damage and hence hydraulic oil leakage.

2

Renew the pump if any of the following symptoms exist:

a

The PTFE coated bearings in the pump bodies, the mount ing flange and t he end c over are w orn through to reveal the bronze backing.

b

The g ear sid e f ac es are sc o red . Of t en contaminated fluid results in a distinct wear step coincident with the gear root diameter. This can normally be felt by drawing a sharp point across the gear side face from the journal towards the tip of the gear.

c

There is a noticeable wear groove on driveshaft

23

where seals

22

run.

d

The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

e

The shaft splines are worn or severely fretted.

f

The gear «cut-in» area in the low pressure side of the pump body is deeper than 0.15 mm (0.006 in) or has a torn or pitted appearance.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

31 — 3

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

31 — 3

S401450

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

31 — 4

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

31 — 4

Fixed Flow

Dismantling and Assembly (continued)

Assembling

When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid.

1

Fit shaft seals

22

into mounting flange

19

, making sure the seal lips are the correct way round as noted in dismantling. Fit circlip

21

into its groove in the flange.

Coat the seal lips with high melting point grease.

Note:

If the seal recess is scored, it is permissible to seal outside diameter with JCB Multigasket to prevent leakage.

2

Stand front body

5

on its rear face. Fit seal

25

and seal energiser

26

into balance plate

24

.

3

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of the front body

5

with the two small holes through the balance plate to the low pressure side of the body (i.e. side with the large 4-bolt port pattern).

4

Insert driveshaft

23

and driven gear

27

into the original bores.

5

Fit balance plate

28

over the driveshaft and gear stub.

Insert seal

29

and seal energiser

30

into the balance plate.

6

Fit O-ring

31

into the groove on mounting flange

19

.

7

Apply a small amount of JCB Multigasket to the face of front body

5

which seals with mounting flange

19

(i.e.

the face containing the clamping bolt holes).

8

Carefully feed mounting flange

19

over driveshaft

23

in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot.

9

Support the front pump assembly on the mounting flange (but not the driveshaft). Fit O-rings

8

into the grooves on the rear face of the front body

5

. Install splined coupling

7

.

10

Fit rear body

6

onto front body

5

in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

11

Fit seal

16

and seal energiser

17

into balance plate

15

.

Ensuring that the seals do not fall out, carefully feed the balance plate into rear body

6

with the two small holes through the balance plate to the low pressure side (i.e.

side without a port).

12

Fit drive gear

10

so that it locates with splined coupling

7

. Fit driven gear

14.

13

Fit balance plate

11

in its original position (i.e. with the two small holes to the low pressure side). Fit seal

12

and seal energiser

13

into the balance plate.

14

Fit O-ring

18

into end cover

9

.

15

Ap p ly a small amount of JCB M ult igasket t o t he exposed face of rear body

6

(i.e. the face containing the clamping bolt holes).

16

Fit end cover

9

in its original position, as marked earlier.

17

Install the four bolts

3

, each with a serrated washer

4

, and tighten evenly and progressively to a torque of 90 —

100 Nm (66 — 74 lbf ft).

18

Pour a small amount of clean JCB Special Hydraulic

Fluid into the ports. Check that driveshaft

23

rotates without undue force. If excessive force is required it is possible that one or more of the balance plate seals are trapped, in which case it will be necessary to dismantle and assemble the pump again.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

35 — 1

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

35 — 1

Variable Flow

16

Dismantling and Assembly

11

C

15

13

4

14

5

18

8

A

B

12

10

6

9

17

7

3

18

S272610

S272640

9803/3280

S213160

Purchased from www.WorkshopManuals.co.uk

2

1

Issue 1

Section E

35 — 2

www.WorkshopManuals.co.uk

Hydraulics

Main Pump

Section E

35 — 2

Variable Flow

Dismantling and Assembly

Before removing and dismantling the pump, make sure it is the pump that is at fault. Complete all the necessary checks as detailed in

Service Procedures, Variable Flow Pumps

.

Make sure that the exterior of the pump and working area is t ho ro ug hly c leaned and f ree o f p o ssib le so urc es o f contamination. Following removal of the pump from the machine, transfer it to a clean dirt free environment ready for dismantling.

The variable displacement pump has matched- ground components. For this reason, some items will only be available as a sub-assembly, for instance the barrel and piston assembly.

All the ‘O’ rings, seals and bearings are available in a kit form from your JCB Distributor.

Dismantling

Refer also to

Service Procedures, Variable Flow Pumps —

Renewing Drive Shaft Seal

.

1

Remove capscrews

1

(4 off) and detach the regulator assembly

2

from the pump housing.

2

Mark the position of the port plate

3

to pump housing

4

.

3

Remove socket screws

5

, and remove the port plate together with the valve plate

6

, control piston

7

and stroking piston

8

. Hold the plate in position during removal.

4

Remove taper roller bearing

9

and shim

10

from the drive shaft

11

.

5

Remove the rotary piston assembly

12

from the pump housing. Assembly includes shaft

11

, bearing

15

, and cradle

16

.

6

Remove and discard port plate to pump housing ‘O’ ring

13

.

7

Remove bearing shells

14

and disc

17

.

8

Remove the outer bearing races (not shown) from the pump housing and the port plate. Only remove the races if they are damaged and unserviceable.

9

Lift the valve plate

6

off the port plate, do not lose the dowel pins (not shown).

Inspecting Parts

Generally check all pump parts for damage and/or wear. Any parts that are scored or damaged must be replaced with new ones.

The shaft ‘O’ ring grooves and all sealing faces must be free of burrs and scores. During assembly, make sure that the rotary piston group move freely. Renew all ‘O’ rings and seals.

Assembly

Assembly is generally a reversal of the dismantle procedure, but note the following:

The taper roller bearing must have a preload of 0.0 to

0.05mm (0.0 to 0.002in.). If the original bearing and shim is being fitted no preload adjustment is required. If a new bearing is installed a preload adjustment is required:

Preload Adjustment:

Install a setting shim of known thickness (as shown at

A

). The shim thickness must be manufactured to a tolerance of ± 0.01mm (0.0004in.). In this example the shim thickness is 1.5mm.

Fit the port plate item

3

and finger tighten the socket screws. It is important that the socket screws are tightened evenly and the port plate sits square.

Using feeler gauges measure the gap

B

between the port plate and the pump housing

4

. Measure in more than one position to establish the port plate is fitted evenly. Obtain shim thickness (dimensions in mm):

Example measured gap

Subtract preload

1.26

— 0.05

Total

Known shim thickness

Subtract calculated preload

1.21

1.50

-1.21

SHIM THICKNESS 0.29

When the shim thickness has been calculated, remove the setting shim

A

and fit the required shim (in this instance the shim would be 0.29mm).

Note:

Setting shim

A

is not currently available as a service t o o l. The shim (and t he c alc ulat ed shim ) c an b e manufactured locally. Maintain a tolerance of ± 0.01mm

(0.0004in.).

10

Remove and discard ‘O’ rings

18

.

The lubrication bore relief (item

C

) on the cradle must be fitted on the pressure side of the pump.

11

Remove control piston

7

. Note that the control piston is mounted on the same side as the regulator valve.

Check the control piston and the stroking piston move smoothly.

12

Remove the stroking piston assembly

8

.

Furt her d ismant ling and assemb ly of t he p ump is not recommended.

9803/3280

The regulator valve assembly is currently a non serviceable part.

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 1

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 1

Removal and Replacement

Manual Control

!

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.

3

Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-2

!

DANGER

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

*

4

Uncouple the dump solenoid electrical connector

G

.

Uncouple the electric detent connector

H

(if fitted).

*

5

Loosen and remove the three fixing nuts

J

. Remove the loader valve and spacing washers

C

.

Replacement

Removal

*

Note:

The illustration shows a valve fitted with a bolt on auxilary spool

1

. This item is only fitted to some machines, typically Precision Control machines with extending dipper.

*

1

Operate the valve block levers back and forth to vent residual pressure. On Precision Control machines also operate the extending dipper foot pedal (if fitted).

*

2

Remove clevis pins

A

and nuts

B

to disconnect the control levers from the valve block spools. Disconnect the control cable

D

(if fitted). Undo the lock nut

E

. Undo the housing fixing screws and slide it down the cable.

Remove the pin

F

.

Replacement is a reversal of the removal sequence.

!

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 immediately.

INT-3-1-10/1

After replacement check the main relief valve (M.R.V.) and auxiliary relief valve (A.R.V.) pressure settings.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

B

1 G

A

F

C

J

9803/3280

J

H

E

D

Purchased from www.WorkshopManuals.co.uk

J

A402470

Issue 2*

Section E

50 — 6

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 6

S262710

9

10

11

8

7

3

4

6

5

2

1

14

12

13

9803/3280

Purchased from www.WorkshopManuals.co.uk

S262720

Issue 1

Section E

50 — 7

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 7

Dismantling and Assembly

Main Relief Valve (MRV)

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ rings and back up rings. DO NOT use worn or damaged items.

Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Assembly

Renew all ‘O’ rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Make sure that the ‘O’ rings and back-up rings are fitted the correct way, items

10

and

11

.

Ad just p ressure set t ing as req uired , refer t o

Service

Procedures, Loader Valve — Pressure Testing

.

Torque Settings

Item

3

Nm

5.4

kgf m

0.6

lbf ft

4

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 8

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 8

9803/3280

11

B

A

8

9

10

6

4

5

3

2

1

14

13

12

7

18

17

16

15

Purchased from www.WorkshopManuals.co.uk

S197420

Issue 1

Section E

50 — 9

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 9

Dismantling and Assembly

Auxiliary Relief Valves (ARV) and

Load Hold Check Valves (LHCV)

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

The ARV’s are identical in design but have different pressure settings, refer to

Technical Data

.

The LHCV’s are identical.

Dismantling

When removing ‘O’ rings and seals, use an an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ rings and back up rings. DO NOT use worn or damaged items.

Dismantle sub-assembly

14

from item

1

using a special tool

(see

Service Tools

). The special spanner locates in cross holes

B

.

Make sure that small drilling

A

is not blocked.

Ensure good condition of seating faces on poppet

18

and on the mating face of the valve block.

Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Assembly

Renew all ‘O’ rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Fit back-up ring

13

on the upper side of ‘O’ ring

12

.

Fit flat face of sleeve

9

against shoulder of poppet

10

.

Torque tighten item

14

using the special tool (see

Service

Tools

), until its shoulder seats firmly against item

1

.

Pressure test the relief valves, refer to

Service Procedures,

Loader Valve — Pressure Testing

.

Torque Settings

Item

1

3

15

Nm

65

24

81 kgf m

6.6

2.5

8.3

lbf ft

48

18

60

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 10

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 10

9803/3280

25

14

3

4

23

19

24

26

18

27

15

7

6

5

17

21

16

2

22

11

10

1

9

8

13

12

S197430

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

50 — 11

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 11

Dismantling and Assembly

Unloader Valve

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

When removing ‘O’ rings and seals, use an an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ rings and back up rings. DO NOT use worn or damaged items.

Use a nylon rod to push out spool assembly item

23

, DO

NOT damage spool bore.

Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Assembly

Renew all ‘O’ rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Ensure that the small drilling through the centre of items

23

, is clear.

Shims

21

are intended to limit the maximum pressure setting, the specified pressure setting is achieved by adjusting capnut

15

. If the specified pressure cannot be achieved under test, it is permissible to add shims as required. There MUST be at least one hardened shim next to the spring item

22

.

Do not over-tighten the solenoid assembly, it may effect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table below (items

1

and

5

).

Fit chamfered end of spring

22

against head of pilot poppet item

23

.

Item

1

5

8

12

16

19

Check pressure setting after refitting, refer to

Service

Procedures, Loader Valve — Pressure Testing

.

Check the operation of the hydraulic speed control, refer to

Service Procedures, Loader Valve — Pressure Testing

.

Torque Settings

Nm

6.7

27

81

81

45

34 kgf m

0.7

2.8

8.3

8.3

4.6

3.5

lbf ft

5

20

60

60

33

25

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 12

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 12

8

1

9

6

5

11

10

7

15

14

13

12

4

3

1A

2

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 13

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 13

Dismantling and Assembly

Standard Spool — Manual

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of t he ab ove p oint s may result in p ossib le problems with the valve.

Dismantling

Remove the lever linkage from the tang (lever) end of the spool.

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item

3

, which is a wiper seal and is a press fit in the counterbore.

Care must b e t aken t o ensure t hat t he sp ool

8

is not damaged when removing it from the valve block.

Hold the spool in clamp 992/10100, unscrew bolt

9

and remove spring

12

, spacer

10

and cups

11

and

13

.

Check for surface contamination on the under side of the seal plates

2

and

14

. Clean if necessary. Check for the flatness of the seal plate. If found to be bent — replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).

Assembly

1

Fit the boot

1A

to the seal plate

2

.

2

Fit a new lipseal

4

into the valve block, ensure square.

Fit wiper

3

on top of lipseal.

3

Fit the seal plate and boot assembly to valve block section but do not torque tighten capscrews

1

at this stage. Ensure wiper locates into seal plate.

4

Use clean hydraulic oil as a lubricant. From the bottom, insert sp ool t hrough t he valve b loc k, d o not use excessive force when fitting, a turning motion should ease the spool through the valve block.

5

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot.

Ensure that the tang aligns with the control rod and that the boot is not distorted and is located in the spool land.

6

Torque tighten cap screws

1

.

7

When fitting bolt

9

, clean the threads thoroughly using

JCB Cleaner/Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer to the threads of the spool.

8

Make sure that all the parts move freely, check that item

10

does not interfere with item

13

.

9

Renew ‘O’ ring

15

. Make sure the ‘O’ ring is not trapped or damaged.

10

Fit seal

15

and seal plate

14

to the valve block section.

Torque tighten capscrew

5

on completion.

Re-connect the lever mechanism to the tang (lever) end of the spool.

Run the engine and inspect the valve for external leaks.

Torque Settings

5

9

Item

1

Nm

9.5

9.5

9.5

kgf m

0.96

0.96

0.96

lbf ft

7

7

7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 14

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 14

9803/3280

13

1

15

4

2

5

3

20

14

23

18

17

22

19

10

16

9

11

8

12

7

21

6

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 15

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 15

Dismantling and Assembly

Float Spool — Manual

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

Remove the lever linkage from the tang (lever) end of the spool.

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item

4

, which is a wiper seal and is a press fit in the counterbore.

Care must be taken to ensure that the spool

13

is not damaged when removing it from the valve block.

Carefully remove collar

9

and collect detent balls

10

.

Using tool 992/10100 to hold the spool, remove circlip

16

, plug

17

, ball

18

and spring

19

. Unscrew detent pin

20

and remove spring

22

and cups

21

and

23

.

Check for surface contamination on the under side of the seal plates

3

and

14

. Clean if necessary. Check for the flatness of the seal plate. If found to be bent — replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).

Assembly

1

Fit the boot

2

to the seal plate

3

.

2

Fit a new lipseal

5

into the valve block, ensure square.

Fit wiper

4

on top of lipseal.

3

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews

1

at this stage. Ensure wiper locates into seal plate.

4

Use clean hydraulic oil as a lubricant. From the bottom, insert sp ool t hrough t he valve b loc k, d o not use excessive force when fitting, a turning motion should ease the spool through the valve block.

5

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot.

Ensure that the tang aligns with the control rod and that the boot is not distorted and is located in the spool land.

6

Torque tighten cap screws

1

.

7

When fitting detent pin

20

, clean the threads thoroughly using JCB Cleaner/Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and

Sealer to the threads of the spool.

8

Apply grease liberally balls

10

, this will help to hold the balls in position whilst assembling.

9

Renew ‘ O’ ring

15

. M ake sure t he ‘ O’ ring is not trapped or damaged.

10

Fit seal

15

and seal plate

14

to the valve block section.

Torque tighten capscrew

6

on completion.

Re-connect the lever mechanism to the tang (lever) end of the spool.

Run the engine and inspect the valve for external leaks.

Torque Settings

Item

1

6

20

Nm

9.5

9.5

9.5

kgf m

0.96

0.96

0.96

7

7 lbf ft

7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 16

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 16

12

1

3

17

16

15

14

8

13

7

1A

4

11

10

18

9

2

5

6

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 17

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 17

Dismantling and Assembly

Electric Detent Spool — Manual

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves, for instance, item

3

, which is a wiper seal and is a press fit in the counterbore.

Care must be taken to ensure that the spool

12

is not damaged when removing it from the valve block.

Use tool 992/10100 to hold the spool, remove circlip

13

and

‘clapper’

14

. Unscrew spool end

15

and remove spring

17

with cups

16

and

18

.

Check for surface contamination on the under side of the seal plates

2

,

8

and

10

. Clean if necessary. Check for the flatness of the seal plate. If found to be bent — replace with new (any work previously carried out on this valve may have resulted in the bending of the seal plate).

Assembly

1

Fit the boot

1A

to the seal plate

2

.

2

Fit a new lipseal

4

into the valve block, ensure square.

Fit wiper

3

on top of lipseal.

3

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews

1

at this stage. Ensure wiper locates into seal plate.

4

Use clean hydraulic oil as a lubricant. From the bottom, insert sp ool t hrough t he valve b loc k, d o not use excessive force when fitting, a turning motion should ease the spool through the valve block.

5

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot.

Ensure that the tang aligns with the control rod and that the boot is not distorted and is located in the spool land.

6

Torque tighten cap screws

1

.

7

When fitting spool end

15

, clean the threads thoroughly using JCB Cleaner/Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and

Sealer to the threads of the spool.

8

Make sure that the chamfer on item

14

faces away from the solenoid, item

6

.

9

Renew lipseal

11

. Make sure the lipseal is not trapped or damaged.

10

Fit lipseal

11

and seal plate

10

to the valve block section. Torque tighten capscrew

5

on completion.

Check the operation of the solenoid

6

after assembly by connecting a 12V supply. The spool should be held when it is pushed into the detent position and returned when the supply is disconnected.

Run the engine and inspect the valve for external leaks.

Torque Settings

Item

1

5

15

Nm

9.5

9.5

9.5

kgf m

0.96

0.96

0.96

7

7 lbf ft

7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

50 — 24

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 24

1B

3B

4B

5B

6B

7B

1C

2C

8B

9B

1A

3A

4A

2A

1A

6A

7A

8A

E

5A

12B

11B

10B

2C

1C

9803/3280

A402610

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

50 — 25

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 25

Dismantling and Assembly

Bolt on Auxiliary Spool Section

Body and Spool

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Two dismantling sequences are shown:

Components prefixed

A

— inlet section, valve body and nonreturn valve.

Components prefixed

B

— valve spool components.

The valve spool components can be dismantled and assembled with the valve body

5A

still assembled to the loader valve

E

if required.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

For dismantling and assembly of the auxiliary relief valves

1C

, see

Bolt on Auxiliary Spool Section — Auxiliary Relief

Valves

.

Torque Settings

Item

1A

2A

1B, 3B

1C

Nm

19

45

8 — 11

40 — 49

kgf m

1.9

4.6

0.8 — 1.1

4 — 5

lbf ft

14

33

6 — 8

30 — 36

When Dismantling

When removing ‘O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves.

When dismantling the spool hold a rod through the eye end of the spool to prevent it rotating when undoing the screw at the opposite end.

Inspection

Inspect the valve components for signs of scratches, nicks or any other type of damage. Renew damaged components as required.

When Assembling

Renew ‘O’ ring seals

4A

,

8A

, and

2C

. Make sure the ‘O’ ring seals are not trapped or damaged.

Renew wiper seals

8B

and

11B

, and spool seals

9B

and

12B

, note the correct seal orientation shown at

X

. When fitting seals

9B

and

12B

make sure they are square to the valve body.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

50 — 26

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 26

A402630

10

12

11

14

13

1

2

9

9803/3280

5

7

6

8

4

17

18

16

19

20

15

Purchased from www.WorkshopManuals.co.uk

3

S402620

Issue 1

Section E

50 — 27

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

50 — 27

Dismantling and Assembly

Bolt on Auxiliary Spool Section

Auxiliary Relief Valve (ARV)

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Great care should be taken when dismantling and assembling a valve to avoid the following:-

Contamination

Damage to spools

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

When Dismantling

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

When Assembling

Renew all ‘O’ rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Make sure that the ‘O’ rings and back-up rings are fitted the correct way, items

13, 14

and

19, 20

.

Adjust pressure setting as required, refer to

Service

Procedures, Pressure Testing — MRV and ARV’s

.

Torque Settings

Item Nm

1

62

5

10

5.4 — 8.2

41 — 68

kgf m

6.4

0.55 — 0.83

4.15 — 6.9

lbf ft

46

4 — 6

30 — 50

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

51 — 1

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Hydraulics

Loader Valve — Fixed Flow

www.WorkshopManuals.co.uk

9A

9

9B

8

6

8A

7A

7B

8B 8C

6

7

8D

6

9C

7C

11

A

3

12

A

12

7D

2

5

10

Section E

51 — 1

1

10A

A403910

Issue 1 9803/3280

4

Purchased from www.WorkshopManuals.co.uk

Section E

51 — 2

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 2

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Dismantling

The loader valve block is a ‘sandwich type’, which is made up of a number of separate sections. The illustration shown on the opposite page is intended as a guide to dismantling.

Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable. Make sure that components are assembled in their original positions.

1

Remove the loader valve block from the machine.

2

Remove the three tie rod nuts

1

.

3

Carefully separate and remove the end plate

2

followed by the remaining service sections

3

. If the inlet section

4

is to be replaced, remove and retain the tie rods

5

.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

Ensure that the mating faces of the valve sections are thoroughly clean before assembly.

2

Renew the ‘O’ rings located between the valve sections.

Make sure the ‘O’ ring seals are not trapped or damaged.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

Torque Settings

8C

8D

9A

9B

9C

10

10A

11

12

Item

1

7A

7B

7C

7D

8A

8B

70

70

60

30

10

10

10

10

10

Nm kgf m lbf ft

35 3.6 25.8

10 1 7.4

10

10

10

20

10

1

1

1

2

1

7.4

7.4

7.4

14.8

7.4

1

1

1

1

1

7.1

7.1

6.1

3

7.4

7.4

7.4

7.4

7.4

51.6

51.6

44.3

22.1

Service Spools

Care must be taken to ensure that the spools

6

are not damaged when removing them from the block. Note that all spools may be similar in appearance but must not be interchanged as they are matched to their bores.

Standard Spool

The dismantling and assembly procedures for the standard spool assembly

7

are detailed separately, refer to

Standard

Spool

.

Electric Detent Spool

The dismantling and assembly procedures for the electric detent spool assembly

8

are detailed separately, refer to

Electric Detent Spool

.

Mechanical Detent Spool

The dismantling and assembly procedures for the mechanical detent spool assembly

9

are detailed separately, refer to

Mechanical Detent Spool

.

Auxiliary Relief Valves

The A.R.V’s

10

appear identical but have various pressure settings, refer to

Technical Data

. Ensure that they are correctly adjusted and fitted in their specified positions.

The dismantling and assembly procedures for the ARV’s are detailed separately, refer to

Excavator Valve, Dismantling and Assembly — Auxiliary Relief Valves (ARV’s)

.

Pressure Compensator Valves

Each of the pressure compensator valves

11

can be removed as shown. Note that all valves are identical in appearance. Note that components are not interchangeable.

Load Hold Check Valves

Each of the load hold check valves

12

can be removed as shown. Note that all valves are identical in appearance.

Ensure good condition of seating faces on poppets and on the mating faces in the valve block.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

51 — 3

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 3

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Standard Spool

A A A

LS

P

B

T

B B

A

B

9803/3280

A403690

A403950

3

4

5

2

1

8

16

A404060

Purchased from www.WorkshopManuals.co.uk

6

A403990

Issue 1

11

9

10

7

15

14

13

12

Section E

51 — 4

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 4

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Standard Spool

Removal

It is possible to remove a spool without removing the loader valve block from the machine. The centring spring

11

is at the bottom, so the spool must be removed from the bottom.

1

Gain access to the loader valve and disconnect and blank any hoses or pipes which may interfere with the removal of the spool.

2

Disconnect the control rod linkage from the spool tongue.

3

Remove the screws

1

, boot

2

and plate

3

.

4

Remove the screws

6

, cover

7

and carefully withdraw the spool assembly from the valve body.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Hold the spool assembly in a vice using the spool clamp

(service tool no. TBA, refer to

Service Tools

) as shown at

A

.

2

Unscrew the spool end

9

and remove the centring spring

11

with spring retainers

10

and

12

. It may be necessary to pre-heat the spool to 200° C in an oven or with a heat gun to remove the spool end.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1 Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

3

Renew lip seals

4

and

14

, and ‘O’ rings

5

and

15

.

Note:

The lip seal MUST be fitted carefully onto the end of the spool to ensure that it is not damaged by the spool lands and that its tightness property does not deteriate. The metal part of the seal should be on the outside.

Torque Settings

Item

1

6

9

16

Nm

10 1 7.4

10

10

10

kgf m

1

1

1

lbf ft

7.4

7.4

7.4

Tongue Replacement (if necessary)

1

Hold the spool assembly in a vice using the spool clamp

(service tool no. TBA, refer to

Service Tools

).

2

Loosen the tongue

16

with an open ended wrench as shown at

B

. It may be necessary to pre-heat the spool to 200° C in an oven or with a heat gun to dismantle the spool.

Note:

DO NOT use a welding torch to heat the tongue as deformation of the spool may result.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

51 — 5

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 5

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Electric Detent Spool

A A A

LS

P

B

T

B B

A

B

A404070

3

4

5

2

1

9

A403970

13

12

11

10

6

8

7

18

17

16

15

14

19

9803/3280

A404060

Purchased from www.WorkshopManuals.co.uk

A404000

Issue 1

Section E

51 — 6

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 6

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Electric Detent Spool

Removal

It is possible to remove a spool without removing the loader valve block from the machine. The centring spring

15

is at the bottom, so the spool must be removed from the bottom.

1

Gain access to the loader valve and disconnect and blank any hoses or pipes which may interfere with the removal of the spool.

2

Disconnect the control rod linkage from the spool tongue.

3

Remove the screws

1

, boot

2

and plate

3

.

4

Unscrew the solenoid

6

from the housing

8

. Remove the screws

7

, housing

8

and carefully withdraw the spool assembly from the valve body.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Hold the spool assembly in a vice using the spool clamp

(service tool no. TBA, refer to

Service Tools

) as shown at

A

.

2

Remove the circlip

10

, disc

11

and spring

12

.

3

Unscrew the spool end

13

and remove the centring spring

15

with spring retainers

14

and

16

. It may be necessary to pre-heat the spool to 200° C in an oven or with a heat gun to remove the spool end.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1 Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

3

Renew lip seal

4

and ‘O’ rings

5

and

18

.

Note:

The lip seal MUST be fitted carefully onto the end of the spool to ensure that it is not damaged by the spool lands and that its tightness property does not deteriate. The metal part of the seal should be on the outside.

Torque Settings

Item

1

7

13

19

Nm

10 1 7.4

10

10

10

kgf m

1

1

1

lbf ft

7.4

7.4

7.4

Tongue Replacement (if necessary)

1

Hold the spool assembly in a vice using the spool clamp

(service tool no. TBA, refer to

Service Tools

).

2

Loosen the tongue

19

with an open ended wrench as shown at

B

. It may be necessary to pre-heat the spool to 200° C in an oven or with a heat gun to dismantle the spool.

Note:

DO NOT use a welding torch to heat the tongue as deformation of the spool may result.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

51 — 7

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 7

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Mechanical Detent Spool

A A A

LS

P

B

T

B B

A

B

9803/3280

22

A404080

3

4

5

2

1

8

A404060

Purchased from www.WorkshopManuals.co.uk

A403980

21

20

19

18

17

16

15

14

13

12

11

10

9

7

6

A404010

Issue 1

Section E

51 — 8

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Fixed Flow

Section E

51 — 8

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Mechanical Detent Spool

Removal

It is possible to remove a spool without removing the loader valve block from the machine. The centring spring

16

is at the bottom, so the spool must be removed from the bottom.

1

Gain access to the loader valve and disconnect and blank any hoses or pipes which may interfere with the removal of the spool.

2

Disconnect the control rod linkage from the spool tongue.

3

Remove the screws

1

, boot

2

and plate

3

.

4

Remove the screws

6

, cover

7

and carefully withdraw the spool assembly from the valve body.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Hold the spool assembly in a vice using the spool clamp

(service tool no. TBA, refer to

Service Tools

) as shown at

A

.

2

Use a metal rod (min. length 80 mm x 6 mm diameter) to push on the central ball

10

whilst extracting the detent bush

9

as shown. Mark the orientation of the bush to ensure that it is fitted the correct way round on re-assembly.

3

Carefully remove the balls

10

and

12

, and the spring

11

.

4

Unscrew the spool end

13

and remove the centring spring

16

with spring retainers

15

and

17

. It may be necessary to pre-heat the spool to 200° C in an oven or with a heat gun to remove the spool end.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1 Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

3

Renew lip seal

4

and ‘O’ rings

5

,

19

and

20

.

Note:

The lip seal MUST be fitted carefully onto the end of the spool to ensure that it is not damaged by the spool lands and that its tightness property does not deteriate. The metal part of the seal should be on the outside.

Torque Settings

Item

1

6

13

22

Nm

10 1 7.4

10

10

10

kgf m

1

1

1

lbf ft

7.4

7.4

7.4

Tongue Replacement (if necessary)

1

Hold the spool assembly in a vice using the spool clamp

(service tool no. TBA, refer to

Service Tools

).

2

Loosen the tongue

16

with an open ended wrench as shown at

B

. It may be necessary to pre-heat the spool to 200° C in an oven or with a heat gun to dismantle the spool.

Note:

DO NOT use a welding torch to heat the tongue as deformation of the spool may result.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 1

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 1

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

!

DANGER

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

Replacement

Replacement is a reversal of the removal sequence.

!

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 immediately.

INT-3-1-10/1

After replacement check the auxiliary relief valve (A.R.V.) pressure settings.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (JCB

Threadseal) applied to the threads of the adapter.

Removal

1

Operate the valve block levers back and forth to vent residual pressure.

2

Remove clevis pins

A

to disconnect the control levers from the valve block spools.

3

Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

4

Loosen and remove nuts

B,

spacers

C

, the loader valve and resilient mounts

D

.

A

Inspection

Inspect the resilient mounts

D

for damage, cracking etc. If the mounts are suspect, then replace them with new ones.

B

C D

S273910

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

55 — 2

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 2

Dismantling and Assembly

Priority Inlet Section

7

8

8

7

1

6

2

3

3

3

5

16

17

4

5

5

4

4

14

13

11

12

10

9

14

13

11

12

10

9

18

15

A

17

S276050

16

A276060

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 3

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 3

Dismantling and Assembly

Priority Inlet Section

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

Remove tie rod nuts

1

and end cover

2

. Separate the valve sections

3

take care not to lose shims

5

. Remove and discard ‘O’ rings

4

.

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ rings and back up rings. DO NOT use worn or damaged items.

Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Inspect screen

A

, make sure the screen is clean and free of dirt.

Take care not to lose ball bearing

17

.

If required, the relief valve assembly

9

can be dismantled for cleaning. It is important to note that this relief valve is fitted as a standard part of the inlet section. However, in this application it does not perform any duties. This is because the steer system pressure is controlled by a relief valve in the orbitrol steer unit (see Steering section), NOT relief valve assembly

9

.

After assembling the relief valve, screw the adjusting screw

18

fully into the valve housing. This will ensure assembly

9

does not interfere with the steer system pressure.

Assembly

Renew all ‘O’ rings and back-up rings.

14

15

16

17

18

9

10

11

12

13

6

7

4

5

8

2

3

Item

1

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Make sure that the ‘O’ rings and back-up rings are fitted the correct way, items

11

and

12

ALWAYS fit three shim (item

5

) in between each valve block section as shown.

After assembly, make sure the steering operates correctly.

The steer circuit will always have priority (see descriptions).

Torque Settings

Item

1

7

9

16

Nm

41

67

67

13.5

kgf m

4.1

6.9

6.9

1.38

lbf ft

30

50

50

10

Description

Tie rod nuts

End cover

Valve section

O-ring

Shim

Tie rod

Plug

O-ring

Relief valve assembly

O-ring

O-ring

Back-up ring

Spring

Spool

Expansion plug

Shuttle plug assembly

Ball bearing

Adjusting Screw

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

55 — 4

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 4

Dismantling and Assembly

Auxiliary Spool

7

6

21

22

23

24

8

9

20

13

1

2

3

3

3

7

5

6

8

9

20

26

27

4

5

5

4

21

22

23

24

25

4

19

18

17

15

16

14

S276070

19

18

17

13

15 14

12

10

16

11

12

11

10

26

A276080

27

9803/3280

25

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 5

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 5

Dismantling and Assembly

Auxiliary Spool

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

Remove tie rod nuts

1

and end cover

2

. Separate the valve sections

3

take care not to lose shims

5

. Remove and discard ‘O’ rings

4

.

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves.

Care must be taken to ensure that the spool

13

is not damaged when removing it from the valve block.

Hold the spool in a suitable clamp, unscrew bolt

14

and remove spring

17

, spacer

16

and cups

15

and

18

.

15

16

17

18

19

10

11

12

13

14

7

8

5

6

9

2

3

Item

1

4

20

21

22

23

24

25

26

27

Assembly

Renew all ‘O’ rings and back-up rings.

When fitting bolt

14

, clean the threads then apply a small quantity of JCB Threadlocker & Sealer to the threads of the spool.

When fitting spool seals

19

and

20

refer to the procedure

Fitting Spool Seal

.

ALWAYS fit three shim (item

5

) in between each valve block section as shown.

Run the engine and inspect the valve for external leaks.

Torque Settings

Item

1

6

10

14

21

25

26

Nm

8

8

41

6

67

13.5

13.5

kgf m

4.1

0.55

0.8

0.8

6.9

1.38

1.38

lbf ft

6

6

30

4

50

10

10

Description

Tie rod nuts

End cover

Valve section

O-ring

Shim

Bolt

Dust boot

Dust guard

Seal

Bolt

Washer

Centering spring housing

Spool assembly

Bolt

Spring cup

Spacer

Spring

Spring cup

O-ring

O-ring

Plug

O-ring

Spring

Poppet

Primary shuttle housing

Shuttle plug assembly

Ball bearing

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 6

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 6

Dismantling and Assembly

Loader Shovel Spool

6

26

27

28

29

7

8

9

30

35

21

31

32

33

30

31

32

33

6

1

7

2

8

9

35

3

3

3

26

27

28

29

23

14

18

13

16

15

12 10

11

20

19

24

22

21

25

34

17

14

13

12

36

5

37

38

4

5

11

10

5

4

34

25

24

4

33

32

23

31

22

30

20

18

17

16

15

19

37

S276140

38

36

A276150

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 7

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 7

Dismantling and Assembly

Loader Shovel Spool

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

Remove tie rod nuts

1

and end cover

2

. Separate the valve sections

3

take care not to lose shims

5

. Remove and discard ‘O’ rings

4

.

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves.

Place a suitable rod through the eye end of spool

21

.

Care must be taken to ensure that the spool

21

is not damaged when removing it from the valve block.

Hold the spool in a suitable clamp, Unscrew coupling

22

and remove spring

24

and cups

23

and

25

.

Relief valve assembly

30

can be dismantled for cleaning purposes only. Individual parts for the relief valve are not available (except seal kits).

Assembly

Renew all ‘O’ rings and back-up rings.

Inspect gasket

14

, replace with a new one if required.

When fitting coupling

22

, clean the threads then apply a small quantity of JCB Threadlocker & Sealer to the threads of the spool.

Check the operation of the solenoid

12

after assembly by connecting a 12V supply . The spool should be held when it is pushed into the detent position and returned when the supply is disconnected.

When fitting spool seals

34

and

35

refer to the procedure

Fitting Spool Seal

.

ALWAYS fit three shim (item

5

) in between each valve block section as shown.

Run the engine and inspect the valve for external leaks.

32

33

34

35

36

27

28

29

30

31

37

38

22

23

24

25

26

17

18

19

20

21

12

13

14

15

16

7

8

9

10

11

4

5

2

3

6

Item

1

Torque Settings

Item Nm

1

6

10

15

22

26

,

30

41

6

8

2.7

11

67 kgf m

4.1

0.55

0.8

0.27

1.1

6.9

Description

Tie rod nuts

End cover

Valve section

O-ring

Shim

Bolt

Dust boot

Dust guard

Seal

Bolt

Washer

Detent Solenoid

Tube

Gasket

Capscrew

Washer

Armature Plate

Spring

Centering Spring Housing

O-ring

Spool

Coupling

Spring cup

Spring

Spring cup

Plug

O-ring

Spring

Poppet

Relief valve assembly

O ring

Back-up ring

O-ring

O-ring

O-ring

Primary shuttle housing

Shuttle plug assembly

Ball bearing lbf ft

6

2

30

4

8

50

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 8

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 8

Dismantling and Assembly

Loader Lift Spool

31

32

33

34

7

8

9

27

18

6

1

2

7

6

3

3

3

5

8

9

27

31

32

33

29

4

30

5

5

4

34

28

4

26

24

20

23

19

17

13

12

11

22

21

14

15

16

18

26

25

10

14

13

12

17

16

15

24

22

23

21

25

20

19

11

10

29

A276120

S276110

30

28

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 9

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 9

Dismantling and Assembly

Loader Lift Spool

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO SPOOL

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

Dismantling

Remove tie rod nuts

1

and end cover

2

. Separate the valve sections

3

take care not to lose shims

5

. Remove and discard ‘O’ rings

4

.

When removing ‘ O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the spool or seal grooves.

Care must be taken to ensure that the spool

18

is not damaged when removing it from the valve block.

Hold the spool in a suitable clamp, use a punch to separate detent shaft

19

from coupling

20

. Unscrew coupling

20

and remove spring

22

, spacer

23

and cups

21

and

24

.

Use a suitable press to compress spring

14

and remove retaining ring

12

. Take care not to lose detent balls

16

.

9803/3280

Assembly

Renew all ‘O’ rings and back-up rings.

When fitting coupling

20

, clean the threads then apply a small quantity of JCB Threadlocker & Sealer to the threads of the spool.

When fitting spool seals

26

and

27

refer to the procedure

Fitting Spool Seal

.

ALWAYS fit three shim (item

5

) in between each valve block section as shown.

31

32

33

34

26

27

28

29

30

21

22

23

24

25

16

17

18

19

20

11

12

13

14

15

8

9

6

7

10

Item

3

4

1

2

5

Item

1

6

10

20

28

29

31

Run the engine and inspect the valve for external leaks.

Torque Settings

Nm

8

8

41

6

13.5

13.5

67 kgf m

4.1

0.55

0.8

0.8

1.38

1.38

6.9

Description

Tie rod nuts

End cover

Valve section

O-ring

Shim

Bolt

Dust boot

Dust guard

Seal

Capscrew

Detent housing

Retaining ring

Retainer

Spring

Piston

Detent balls

Washer

Spool assembly

Detent shaft

Pivot coupling

Spring cup

Spring

Spacer

Spring cup

O-ring

O-ring

O-ring

Primary shuttle housing

Shuttle plug assembly

Ball bearing

Plug

O-ring

Spring

Poppet lbf ft

6

6

30

4

10

10

50

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

55 — 10

www.WorkshopManuals.co.uk

Hydraulics

Loader Valve — Variable Flow

Section E

55 — 10

Dismantling and Assembly

Fitting Spool Seal

Use the procedure described below to correctly install the valve spool seals:

1

Lubricate the spool, bore and O-ring groove with JCB

Hydraulic Fluid. Move the spool to the position shown and then install the O-ring

A

in its groove.

1

A

C

2

Move the spool to the position shown and then install the O-ring

B

. It is important to note that the spool must not be moved beyond the position shown, otherwise the edge of the spool (face

C

) may damage the first fitted O-ring (item

A

).

2

B

3

3

Position the spool in its central position as shown. Reassembe the centering assembly, dust boot etc as detailed previously in this section.

A276280

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

60 — 1

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

60 — 1

Removal and Replacement

Manual Control

!

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

!

DANGER

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

Removal

1

Operate the valve block levers back and forth to vent residual pressure.

2

Remove the rear valance.

3

Remove clevis pins

A

to disconnect the control levers from the valve block spools.

4

Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

5

Loosen nuts

B

— do not completely remove the retaining nuts.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

6

Wrap a suitable sling around the valve, make sure that the weight of the valve is supported by the sling.

7

Remove nut s

B

and lower t he valve b loc k t o t he ground.

Replacement

Replacement is a reversal of the removal sequence.

Hoses and pipes (when applicable) must be re-connected and p hased in sam e p o sit io n as rem o val. Ref er t o

Dismantling and Assembly, Hoses and Pipes

.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

After replacement check the auxiliary relief valve (A.R.V.) pressure settings.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

B

9803/3280

A

Purchased from www.WorkshopManuals.co.uk

S401480

Issue 1

Section E

60 — 4

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

60 — 4

Removal and Replacement

Variable Flow

A

B

C

9803/3280

C

C

Purchased from www.WorkshopManuals.co.uk

S278930

Issue 1

Section E

60 — 5

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

60 — 5

Removal and Replacement

Variable Flow

!

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

!

DANGER

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

Removal

1

Sideshift the carriage to one side as shown (sideshift machines only). Lower the backhoe and loader end to the ground and stop the engine.

2

Operate the valve block levers back and forth to vent residual pressure.

3

Remove the hose guide

A

(this makes access to the valve block easier).

3

Remove clevis pins

B

to disconnect the control levers from the valve block spools.

4

Disconnect all hydraulic hoses from the valve block and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

5

Insert two M10 bolts through the eye end spools (three spools each end) as shown. Make sure the bolt has a retaining nut on each end. When the bolts are in place thread suitable slings around the bolts as shown.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

7

Remove nut s

C

and low er t he valve b loc k t o t he ground.

Inspection

Inspect the resilient mounts for damage, cracking etc. If the mounts are suspect, then replace them with new ones.

Replacement

Replacement is a reversal of the removal sequence.

Hoses and pipes (when applicable) must be re-connected and p hased in sam e p o sit io n as rem o val. Ref er t o

Dismantling and Assembly, Hoses and Pipes

.

!

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 immediately.

INT-3-1-10/1

After replacement check the auxiliary relief valve (A.R.V.) pressure settings.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

60 — 6

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

60 — 6

11

11

11

11

15

14

11

11

9

13

15

6

B

7

3

4

3

5

11

11

15

10

1

A

2

2

A402450

9803/3280

8

A402460

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

60 — 7

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

60 — 7

Removal and Replacement

Precision Control (Servo)

!

DANGER

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

Disconnect the stabiliser spool control cables

3

as follows:

1

Undo the lock nut

4

.

2

Undo the housing retaining screws

5

and slide the housing down the cable.

3

Push out the cable connecting pin

6

and disconnect the cable at the spool. Tie the cables out of harms way.

Removal

It is recommended that the valve is removed complete with its mounting plate. The assembly is lowered down and then out from under the rear on the machine. Before commencing make sure that there is sufficient clearance between the machine and the ground. If necessary raise the rear of the machine using the stabilisers. Chock the machine securely, remembering to leave access for removal of the valve assembly.

Remove the excavator valve as follows:

1

For access remove bolts

7

and tie hose guard

8

out of the way.

2

Uncouple electrical connection to the rear horn

9

.

3

Uncouple electrical connection

10

to the hydraclamp solenoid.

The illustration is viewed from the bottom.

Before proceding, vent the hydraulic pressure as follows:

1

Stop the engine. With the operator seat set in the rear facing position (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams.

2

Operate the stabiliser controls several times to vent pressure from the stabiliser rams.

4

Record the phasing of the pilot hoses

11

connected at the top and bottom of the excavator valve. The hoses should be labelled, if not label each hose before disconnecting, this will ensure correct position when refitting. Disconnect all hydraulic pilot hoses from the valve block and plug all open ends and ports to prevent ingress of dirt.

5

Record the phasing of the service hoses connected at the front of the excavator valve. Label each hose before disconnecting, this will ensure correct position when refitting. Disconnect all the hoses from the valve block and plug all open ends and ports to prevent ingress of dirt.

3

Turn the starter switch to the OFF position and remove the key.

!

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

6

Disconnect the inlet

13

and tank return

14

hoses from the valve block, plug all open ends and ports to prevent ingress of dirt.

7

Loosen the three mounting plate bolts

15

— DO NOT completely remove the retaining bolts.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

To avoid damage to the pilot supply valve (shown at

A

), remove it as follows:

1

Carfully tag all the hoses connected at the valve. Record the phasing. Disconnect the hoses.

8

Open the rear window. Remove the access plate in the cab floor above the excavator valve. Attach a suitable sling to the mounting bracket slinging point, make sure that the weight of the valve is supported by the sling

(shown at

B

).

9

Remove bolts

15

and lower the valve block to the ground.

2

Uncouple the solenoid electrical connector

1

.

3

Undo the two fixing bolts

2

and remove the valve.

9803/3280

10

If the hose adaptors are going to be removed from the valve block, label before removing to ensure replacement in the correct ports. Record the positions of any restrictors.

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section E

60 — 8

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

11

11

11

11

15

Section E

60 — 8

14

11

11

9

13

15

6

B

7

3

4

3

5

11

11

15

10

1

A

2

2

A402450

9803/3280

8

A402460

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

60 — 9

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

60 — 9

Removal and Replacement (Cont’d)

Precision Control (Servo)

Replacement

Replacement is a reversal of the removal sequence.

Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.

!

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 immediately.

INT-3-1-10/1

After replacement check the auxiliary relief valve (A.R.V.) pressure settings.

Torque Settings

Item

5

Nm

8 — 11

kgf m

0.8 — 1.1

lbf ft

6 — 8

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

61 — 1

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

61 — 2

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 2

Dismantling and Assembly

Manual Control

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Check Valves

Each of the identical load hold check valves

4R

to

4W

can be removed as shown at

4W.

Make-up check valve

4X

is a smaller size but otherwise identical.

Ensure good condition of seating faces on poppets

4

and

8

and on the mating faces in the valve block.

Spools

Spools

4A

,

4B

,

4E

and

4F

are identical but must not be interchanged as they are matched to their bores. Stabiliser spools

4C

and

4D

are identical to each other but different from the excavator spools.

All spools have the same centring and sealing components items

9

to

21

.

To completely dismantle a spool, follow the sequence

9

to

21

. To prevent spool rotation when turning screw

15

, hold a rod through the eye end of the spool.

If only renewing the seals, dismantle as far as cap

14

then remove items

15

to

22

as an assembly.

Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of the spool.

Apply JCB Threadlocker and Sealer to threads of screw

15

.

Relief Valves

A.R.V’s

4H

to

4P

appear identical but have various pressure settings, refer to

Technical Data

. Ensure that they are correctly adjusted and fitted in their specified positions.

Relief valve dismantling and assembly procedures are detailed separately.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

Assembly

1

Fit the boot

10

to the seal plate

11

.

2

Fit a new lipseal

12A

into the valve block, ensure square. Fit wiper

12

on top of lipseal.

3

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews

9

at this stage. Ensure wiper locates into seal plate.

4

Use clean hydraulic oil as a lubricant. From the bottom, insert spool through the valve block, do not use excessive force when fitting, a turning motion should ease the spool through the valve block.

5

Check that the tang end of the spool passes through the boot without dislodging or damaging the boot.

Ensure that the tang aligns with the control rod and that the boot is not distorted and is located in the spool land.

6

Torque tighten cap screws

9

.

7

When fitting bolt

15

, clean the threads thoroughly using

JCB Cleaner/Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer to the threads of the spool.

8

Make sure that all the parts move freely, check that item

16

does not interfere with item

18

.

9

Renew ‘O’ ring

21

and seal

20

. Make sure the ‘O’ ring and wiper seal are not trapped or damaged.

10

Fit seal

20

and seal plate

19

to the valve block section.

Torque tighten capscrew

13

on completion.

Re-connect the lever mechanism to the tang (lever) end of the spool.

Run the engine and inspect the valve for external leaks.

Torque Settings

Item

1

5

9

13

15

23

Nm

122

kgf m lbf ft

12.4

90

80 8.3

60

9.5 0.96 7

7

11

95

0.7

1.1

10

5

8

70

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

61 — 3

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 3

Auxiliary Relief Valves

4Q

4N

4L 4J

4P 4M

4K 4H

B

9803/3280

A

S161700

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

61 — 4

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 4

Dismantling and Assembly

Auxiliary Relief Valves

Eight A.R.V’s are fitted at positions

4H

to

4Q.

These are identical in design but have various pressure settings, refer to

Technical Data

.

Note:

Valve

4Q

is only fitted to machines equipped with a

Powerbreaker.

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Dismantling

Dismantle sub-assembly

14

from item

1

using a special tool

(see

Service Tools

). The special spanner locates in cross holes

B

.

Dismantle sub-assembly

14

into its component parts.

Make sure that small drilling

A

is not blocked.

Discard old and worn O-rings and back-up rings.

Assembly

Renew all O-rings and back-up rings.

Lubricate O-rings and back-up rings with JCB Hydraulic

Fluid.

Fit back-up ring

13

on the upper side of ‘O’ ring

12

as shown in the inset.

Fit flat face of sleeve

9

against shoulder of poppet

10.

Torque tighten item

14

using the special tool (see

Service

Tools

), until its shoulder seats firmly against item

1

.

Pressure test the relief valves, refer to

Service Procedures,

Excavator Valve — Pressure Testing

.

Torque Settings

Item

1

3

Nm

65

24 kgf m lbf ft

6.6

48

2.5

18

A.R.V. Position Key

Slew Right

Slew Left

Boom Rod

Boom Head

Dipper Rod

Dipper Head

Bucket Rod

Bucket Head

4L

4N

4M

4Q

4P

JCB

4H

4J

4K

Control Layout

ISO

4H

4J

4M

4N

4L

4K

4Q

4P

Case

4H

4J

4M

4N

4K

4L

4Q

4P

4L

4N

4M

4P

4Q

Ford

4H

4J

4K

Note:

The bucket rod side A.R.V. is only fitted to machines equipped with a Powerbreaker.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

61 — 5

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 5

Dismantling and Assembly

Hydraclamp Valve — (Sideshift Machines)

(Not Precision Control Machines)

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO POPPET AND SEAT

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

When removing ‘O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL ‘O’ rings DO NOT use worn or damaged items.

Note that the hydraclamp comprises two separate valve assemblies; 1) the check valve assembly (items

1

to

8

); 2) the solenoid assembly (items

11

to

14

).

Dismantling

Loosen nut

1

(turn anti-clockwise) and then remove the check valve assembly from the valve block. If required, the check valve assembly can be dismantled into its component parts (items

1

to

8

).

Inspect the valve components for scratches, nicks or any other type of damage, particularly on the poppet and seat faces. Replace with new if required.

Assembly

Renew all ‘O’ rings. The parts microfiche will identify the correct seal kit part numbers for items

2

,

2A

,

4

,

6

,

10

and

14

.

Fit seal

2A

with the recess towards ‘O’ ring

2

, as shown at

A

.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Ensure that the small drilling through the centre of item

3

, is clear.

Do not over-tighten the solenoid assembly, it may affect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table below (items

11

and

13

).

Check the operation of the electric hydraclamp, refer to

Circuit Descriptions, Excavator Valve — Manual Control —

Hydraclamp Valve Operation

.

Torque Settings

3

5

Item

1

11

13

Nm

13.5

24.5

13.5

5.5

24.5

kgf m

1.4

2.5

1.4

0.5

2.5

5

6

7

8

lbf ft

10

18

10

4

18

2

A

2A

10

9

3

S217500

1

14

13

12

11

2 4

2A

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section E

61 — 6

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 6

Dismantling and Assembly

— Hoses and Pipes (Sideshift Valve)

Refer to

Excavator Valve, Removal and Replacement

for valve block removal and replacement procedure. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.

CROWD

BOOM

STABILISER DIPPER

SLEW

BOOM

DIPPER

CROWD

SLEW

CROWD

BOOM STABILISER

ISO EXCAVATOR VALVE

DIPPER

CROWD

DIPPER

STABILISER BOOM

SLEW

SLEW

CLAMP

BOOM

DIPPER

CROWD

SLEW

S270740

BOOM

DIPPER

CROWD

SLEW

CROWD

DIPPER

STABILISER

JCB EXCAVATOR VALVE

9803/3280

BOOM

SLEW

Purchased from www.WorkshopManuals.co.uk

CLAMP

BOOM

DIPPER

CROWD

SLEW

S270750

Issue 2*

Section E

61 — 7

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

61 — 7

Dismantling and Assembly

— Hoses and Pipes (Centremount Valve)

Refer to

Excavator Valve, Removal and Replacement

for valve block removal and replacement procedure. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.

CROWD

BOOM

STABILISER DIPPER

SLEW

CROWD

ISO EXCAVATOR VALVE

BOOM

STABILISER

DIPPER SLEW

CROWD

DIPPER

STABILISER

BOOM

SLEW

S273370

CROWD

DIPPER

STABILISER

BOOM

SLEW

JCB EXCAVATOR VALVE

9803/3280

Purchased from www.WorkshopManuals.co.uk

S273380

Issue 2*

Section E

62 — 1

RF

1

RE

1

RF

2

RE

2

G F E

Hydraulics

Excavator Valve

RB

1

RA

1

K

JG JF JE JD JC JB JA

RB

2

RA

2

D C

A402500

B www.WorkshopManuals.co.uk

N

Section E

62 — 1

G1

G3

G4

G2

G F E D C B

(B) (B) (G) (G)

B5

B6

B7

B1

B2

B3

B4

A

A2

A1

H

A3

A4

A5

A6

A7

A8

A9

A10

H1

H2

H3

H4

H5

H6

K

A H

G5

9803/3280

L

M

A402510

Purchased from www.WorkshopManuals.co.uk

G6

G15

G14

G13

G12

G11

G10

G9

G8

G

G7

B8

B

B14

B13

B12

B11

B10

B9

A11

A

A21

A20

A19

A18

A17

A16

A15

J5

J4

J3

J2

J1

JA

A14

A13

A12

A402600

Issue 2*

Section E

62 — 2

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 2

Dismantling and Assembly

Precision Control (Servo)

(Machines up to serial no. 931159)

Introduction

The numerical sequence shown on the illustration is intended as a guide to dismantling. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable.

Make sure that components are assembled in their original positions.

For assembly the sequence should be reversed.

Load Sense (Isolator/Compensator) Valves

Each of the load sense valves

JA

to

JG

can be removed as shown at

JA.

Note that all valves are identical in appearance except valve

JE

. This valve is of the same configuration but is dimensionally different. Note that components are not interchangeable, see the introduction above.

Spools

Note that the not all the spools are shown with their components. This is because some spool assemblies are of the same configuration:

For spools

F

and

E

see spool

B

.

For spools

D

and

C

see spool

G

. Note that the spools are inverted relative to spool

G

.

Stabiliser spools

1D

and

4E

are identical to each other but different from the excavator spools. Spools must not be interchanged as they are matched to their bores

To dismantle spools

C

,

D

and

G

hold a rod through the eye end of the spool to prevent it rotating when undoing the screw at the opposite end. To dismantle spools

B

,

E

and

F

use allen keys in both screws, holding one whilst undoing the other. After removing one screw, hold the spool using service tool 992/10100 and then undo the remaining screw.

It is strongly recommended that that spool

A

is not dismantled. The spool has additional valve components in each end and can easily be damaged when dismantling. If the spool is damaged then the valve must be renewed. Only attempt to dismantle the spool in exceptional circumstances.

Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of the spool.

Note that the breather groove

N

in the seal retaining plates

G3

must be orientated facing the rear mounting face of the valve block

Relief Valves

A.R.V’s

RA

to

RF

appear identical but have various pressure settings, refer to

Technical Data

. Ensure that they are correctly adjusted and fitted in their specified positions.

Relief valve dismantling and assembly procedures are detailed separately.

Bypass Compensator Valve

The bypass compensator valve is shown at

H

. Note that the assembly

L

is a blanking spool and would not normally need to be removed.

Load Sense Drain Regulator and Relief Valve

The dismantling and assembly procedure for the drain regulator and relief valve assembly

K

is detailed separately, see

Drain Regulator and Relief Valve

.

When assembling apply JCB Threadlocker to the following components:

A2

A13

G8

Torque Settings

Item

A1

A2

A11

A13

B1

B3

Nm

8 — 11

kgf m lbf ft

0.8 — 1.1

6 — 8

8 — 11

8 — 11

8 — 11

8 — 11

0.8 — 1.1

0.8 — 1.1

0.8 — 1.1

0.8 — 1.1

6 — 8

6 — 8

6 — 8

6 — 8

17 — 21 1.7 — 2.1

12.5 — 15.5

B8

B10

G1

G6

G8

8 — 11 0.8 — 1.1

6 — 8

17 — 21 1.7 — 2.1

12.5 — 15.5

8 — 11

8 — 11

8 — 11

0.8 — 1.1

0.8 — 1.1

0.8 — 1.1

6 — 8

6 — 8

6 — 8

H1

JA

K

M

58 — 72

58 — 72

58 — 72

58 — 72

6 — 7.3

6 — 7.3

6 — 7.3

6 — 7.3

RA — RF

58 — 72 6 — 7.3

43 — 53

43 — 53

43 — 53

43 — 53

43 — 53

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section E

62 — 3

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 3

1

2

3

4

5

6

14

8

7

8

7

11

9803/3280

A402640

Purchased from www.WorkshopManuals.co.uk

6

13

12

11

10

9

Issue 3*

Section E

62 — 4

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 4

Dismantling and Assembly

Precision Control (Servo)

(Machines up to serial no. 931159)

Load Sense Drain Regulator and Relief Valve

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Note that components

6 — 13

can be dismantled and assembled without disturbing components

1 — 5

. If components

1 — 5

are dismantled, the valve must be reset to the correct operating pressure after assembly.

For assembly the sequence should be reversed.

Great care should be taken when dismantling and assembling a valve to avoid the following:-

Contamination

Damage to spools

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

When Dismantling

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

When Assembling

Renew all ‘O’ rings and back-up rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Make sure that the ‘O’ rings and back-up rings are fitted the correct way, items

7

and

8

.

Be sure to fit filter screen

11

the correct way round.

Adjust pressure setting as required.

Torque Settings

Item Nm

1

8 — 11

kgf m

0.8 — 1.1

lbf ft

6 — 8

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section E

62 — 5

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 5

Dismantling and Assembly

Precision Control (Servo)

(Machines up to serial no. 931159)

Hydraclamp Valve

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

The following points MUST be avoided when dismantling and assembling the valve:

•

CONTAMINATION

•

DAMAGE TO BALL SEAT AND PISTON

•

DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

When removing ‘O’ rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL ‘O’ rings DO NOT use worn or damaged items.

Note that the hydraclamp comprises two separate valve assemblies; the clamp valve assembly shown at

A

and the solenoid assembly shown at

B

.

Dismantling

Unsecrew the clamp valve assembly

A

from the excavator valve block. Withdraw the piston

3

from the excvator valve block, if necessary use thin nose pliers.

Hold the body

1

and undo the spring retaining plug

4

.

Withdraw the spring

5

and ball

6

.

Undo the nut

7

and remove solenoid coil

8

. Undo the valve stem

9

.

Make sure that all components and associated cross drillings are clean and free from debris.

Inspect the valve components for scratches, nicks or any other type of damage, particularly on the ball and seat faces.

Carefully inspect the outside diameter of the piston 3 and its bore in the excavator valve block for damage or excessive wear. Renew components as required.

Assembly

Renew all ‘O’ rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Make sure that all the parts move freely.

Ensure that the small drilling

C

in the piston

3

is clear.

Do not over-tighten the solenoid assembly, it may affect the operation of the solenoid, use the spanner flats and torque tighten to figure indicated in the table.

Check the operation of the electric hydraclamp, refer to

Circuit Descriptions, Excavator Valve — Precision Control

— Hydraclamp Valve Operation

.

Torque Settings

Item

4

7

9

Nm

8 — 11

4.7 — 6.1

41 — 48

kgf m

0.8 — 1.1

0.5 — 0.6

4.1 — 5

lbf ft

6 — 8

3.5 — 4.5

30 — 36

A

1 4 5

A402950

2 6 C 3

8

7

9

10

B

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

62 — 20

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Hydraulics

Excavator Valve

www.WorkshopManuals.co.uk

13

12

14

13

14A

9803/3280

5

9

4

7

8

11A

3

6

11

10

Purchased from www.WorkshopManuals.co.uk

2

6A

A403840

1

Section E

62 — 20

Issue 1

Section E

62 — 21

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 21

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Dismantling

The excavator valve block is a ‘sandwich type’, which is made up of a number of separate sections. The illustration shown on the opposite page is intended as a guide to dismantling. Be sure to note the location of all components when dismantling. Although some components may appear to be identical they are not interchangeable. Make sure that components are assembled in their original positions.

1

Remove the excavator valve block from the machine.

2

Remove the three tie rod nuts

1

.

3

Carefully separate and remove the outlet section

2

followed by the remaining service sections

3

. If the inlet section

4

is to be replaced, remove and retain the tie rods

5

.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

Ensure that the mating faces of the valve sections are thoroughly clean before assembly.

2

Renew the ‘O’ rings located between the valve sections.

Make sure the ‘O’ ring seals are not trapped or damaged.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

Torque Settings

Item

1

6A

7

8

9

10

11

11A

12

13

14

14A

70

60

30

20

45

Nm kgf m lbf ft

35 3.6 25.8

10 1 7.4

20

45

100

70

70

2

4.6

10.2

7.1

7.1

14.8

33.2

73.8

51.6

51.6

3

2

7.1

6.1

4.6

51.6

44.3

22.1

14.8

33.2

Service Spools

Each of the service spools

6

can be removed as shown.

Care must be taken to ensure that the spool is not damaged when removing it from the block. Note that all spools are similar in appearance but must not be interchanged as they are matched to their bores. All spools have the same centring and sealing components.

Flow Regulator Valve

The dismantling and assembly procedures for the flow regulator valve

7

are detailed separately, refer to

Flow

Regulator Valve

.

Load Sense Relief Valve

The dismantling and assembly procedures for the load sense relief valve

8

are detailed separately, refer to

Load

Sense Relief Valve

.

Flushing Valve

The flushing valve

9

can be removed as shown.

Auxiliary Relief Valves

The A.R.V’s

10

appear identical but have various pressure settings, refer to

Technical Data

. Ensure that they are correctly adjusted and fitted in their specified positions.

The dismantling and assembly procedures for the ARV’s are detailed separately, refer to

Auxiliary Relief Valves (ARV’s)

.

Anti-cavitation Valve

The dismantling and assembly procedures for the anticavitation valve

11

are detailed separately, refer to

Anticavitation Valve

.

Pressure Compensator Valves

Each of the pressure compensator valves

12

can be removed as shown. Note that all valves are identical in appearance. Note that components are not interchangeable.

Load Hold Check Valves

Each of the load hold check valves

13

can be removed as shown. Note that all valves are identical in appearance.

Ensure good condition of seating faces on poppets and on the mating faces in the valve block.

Hydra-clamp Solenoid Valve

The hydra-clamp solenoid valve

14

can be removed as shown.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

62 — 22

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 22

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Flow Regulator Valve

Removal

It is possible to remove a valve without removing the excavator valve block from the machine.

Note

: If removing components from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. With the operator seat locked in the rear facing position and with the arm rests raised forward (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

1

Gain access to the excavator valve and disconnect and blank any hoses or pipes which may interfere with the removal of the flow regulator valve.

2

Unscrew the flow regulator valve from the excavator valve block. Cover the ports to prevent the ingress of dirt and remove to a clean working area.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Unscrew and remove top plug

1

.

2

Carefully remove shims

2

, spring

3

and piston

4

.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1

Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

2

Clean the filter gauze

5

fitted in the end of the valve body.

Note:

If any part other than ‘O’ rings are damaged the entire valve must be renewed.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Renew all ‘O’ rings and back-up rings.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

4

Be sure to fit filter gauze

5

the correct way round.

5

A403850

1

2

3

4

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

62 — 23

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 23

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Load Sense Relief Valve

Removal

It is possible to remove a valve without removing the excavator valve block from the machine.

Note

: If removing components from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. With the operator seat locked in the rear facing position and with the arm rests raised forward (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

1

Gain access to the excavator valve and disconnect and blank any hoses or pipes which may interfere with the removal of the load sense relief valve.

2

Unscrew the load sense relief valve from the excavator valve block. Cover the ports to prevent the ingress of dirt and remove to a clean working area.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Loosen locknut

1

, unscrew and remove adjuster nut

2

and adjuster screw

3

.

2

Carefully remove spring

4

and poppet

5

from valve body.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1

Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

Note:

If any part other than ‘O’ rings are damaged the entire valve must be renewed.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Renew all ‘O’ rings and back-up rings.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

4

Adjust the pressure setting as required. Refer to

Service Procedures, Pressure Testing, Load Sense

Relief Valve

.

A403860

1

2

4

5

3

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

62 — 24

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 24

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Auxiliary Relief Valves (ARV’s)

Removal

It is possible to remove a valve without removing the excavator valve block from the machine.

Note

: If removing components from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. With the operator seat locked in the rear facing position and with the arm rests raised forward (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

1

Gain access to the excavator valve and disconnect and blank any hoses or pipes which may interfere with the removal of the auxiliary relief valve(s).

2

Unscrew the auxiliary relief valve(s) from the excavator valve block. Cover the ports to prevent the ingress of dirt and remove to a clean working area.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Prise off plastic locking cap.

2

Loosen locknut

1

and remove adjuster screw

2

.

3

Carefully remove spring

3

and poppet

4

.

4

Unscrew upper valve body

5

and remove springs

6

and piston

7

.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves. Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1

Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

Note:

If any part other than ‘O’ rings are damaged the entire valve must be renewed.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Renew all ‘O’ rings and back-up rings.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

4

Adjust the pressure setting as required. Refer to

Service Procedures, Auxiliary Relief Valve — Setting

.

A403870

1

2

3

6

4

5

7

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

62 — 25

www.WorkshopManuals.co.uk

Hydraulics

Excavator Valve

Section E

62 — 25

Dismantling and Assembly

Precision Control (Servo)

(Machines from January 2003)

Anti-cavitation Valve

Removal

It is possible to remove a valve without removing the excavator valve block from the machine.

Note

: If removing components from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. With the operator seat locked in the rear facing position and with the arm rests raised forward (for backhoe operation), switch the starter to ON without starting the engine. Operate the joystick controls several times to vent the hydraulic pressure from the servo system and backhoe rams. Turn the starter switch to the OFF position and remove the key.

1

Gain access to the excavator valve and disconnect and blank any hoses or pipes which may interfere with the removal of the anti-cavitation valve.

2

Unscrew the anti-cavitation valve from the excavator valve block. Cover the ports to prevent the ingress of dirt and remove to a clean working area.

Dismantling

Great care should be taken when dismantling and assembling a valve to avoid the following:-

•

Contamination

•

Damage to spools

•

Damage to seal grooves

Any of the above may result in possible problems with the operation of the valve.

1

Unscrew and carefully remove the top nut

1

complete with piston

2

from the valve body.

2

Remove the piston

2

and spring

3

from the top nut spindle.

Note:

When removing ‘O’ Rings and seals, use an appropriatly rounded tool that WILL NOT cause any damage to the seal grooves.

Discard ALL ‘O’ Rings and back-up rings. DO NOT use worn or damaged items.

Inspection

1

Inspect the valve components for scratches, pitting, corrosion or any other type of damage.

Note:

If any part other than ‘O’ rings are damaged the entire valve must be renewed.

Assembly

Assembly is the reverse of the dismantling sequence.

1

Clean the valve components in an appropriate solvent.

2

Renew all ‘O’ rings and back-up rings.

3

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

3

2

1

A403880

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

70 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hose Burst Protection Valves

Section E

70 — 1

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

!

DANGER

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

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and stop the engine.

Note

: Refer to

Service Procedures, Hose Burst Protection

Valves, Lowering a Load — In a Failure Condition

for lowering a load with engine failure or a burst hose.

2

Turn the manual over-ride screw fully clockwise.

3

Operate the main service control levers back and forth to vent residual pressure. For instance, if the HBPV is fitted on the boom or dipper then operate the backhoe control levers. If the HBPV is fitted on the loader arms then operate the loader control levers.

4

Disconnect all hydraulic hoses from the HBPV and plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

5

Undo the retaining clips

A

and remove the HBPV.

Replacement

Replacement is a reversal of the removal sequence.

!

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 immediately.

INT-3-1-10/1

After refitting the valve to the machine, ensure that the valve operates correctly, refer to

Service Procedures, Hose

Burst Protection Valves — Checking

.

A

A

324250

A

9803/3280

323590

Purchased from www.WorkshopManuals.co.uk

A260734

Issue 1

Section E

70 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hose Burst Protection Valves

Section E

70 — 2

Dismantling and Assembly

— Loader Lift Ram

This procedure applies to Hose Burst Protection Valves fitted to the loader arm rams ONLY.

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Dismantling

If possible, avoid disturbing pressure settings, remove cartridges by unscrewing hexagons

1

and

13

and do not remove capnuts

3

and

16

.

Spool

2

and check valve

11

each have a Teflon ring fitted

(items

A

and

B

respectively). These Teflon rings should only be removed and replaced with new ones if they are damaged.

Do not try to dismantle items

20

,

21

and

22

(these items are shown for pictorial reference only). To clean, use a nonmetallic probe to move the ball

21

against spring

22

whilst assembly

17

is submersed in cleaning fluid.

Check condition of all visible seating faces. If any are damaged, renew complete cartridge or valve assembly.

Check valve bores and spools for nicks, scratches or scoring, if necessary, renew complete cartridge or valve assembly.

Assembly

DO NOT apply JCB Threadlocker and Sealer or any other type of locking fluid to the threads of item

17

. The threads form an integral part of the valve operating sequences applying locking fluid to the threads will seriously effect the operation of the valve.

Ensure that the small drilled holes

C

and

D

in items

2

and

17

respectively are not blocked.

Renew all seals. If fitting new Teflon rings

A

&

B

, use a conical guide, such as item

E

, to expand the rings gradually.

Complete the ring fitting procedure as quickly as possible, otherwise the ring will stretch. See below.

Note:

There is an O-ring

F

fitted underneath each Teflon ring, if the Teflon rings are to be renewed, make sure that new O-rings are fitted first.

After assembly, make sure that the valve parts move freely, if they don’t, check that all the seals are correctly fitted.

After refitting the valve to the machine, ensure that pressure settings are correct, see

Technical Data

page, and check that the valve operates correctly.

If the pressure settings were disturbed, then the valve must be re-set, refer to

Service Procedures, Hose Burst

Protection Valves, Pressure Testing — Loader Lift Ram

.

9803/3280

E

B

325780

F

11

Purchased from www.WorkshopManuals.co.uk

A183490

Issue 1

Section E

70 — 3

www.WorkshopManuals.co.uk

Hydraulics

Hose Burst Protection Valves

Section E

70 — 3

Dismantling and Assembly (Cont’d)

— Boom and Dipper Rams

This procedure applies to Hose Burst Protection Valves fitted to the boom/dipper rams ONLY.

There is no servicing permitted on this valve apart from the removing and fitting a new check valve assembly

A

when the seal

B

has been broken.

DO NOT use the machine with a broken seal.

If the assembly is fitted to the machine, before removing the check valve

A

, operate the main service control levers back and forth to vent residual pressure.

After fitting a new check valve ensure that the valve assembly operates correctly, refer to S

ervice Procedures,

Hose Burst Protection Valves — Checking

.

B

A

S327320

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

75 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

75 — 1

Removal and Replacement

— Loader Lift Ram

A

B

C

F

E

G

D

S266330

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

75 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

75 — 2

Removal and Replacement

— Loader Lift Ram

Removal

!

WARNING

The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a ‘scissor’ point with the loader arm. Make sure the interlevers are securely blocked when working in the loader arm area.

BF 2-1

1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

2

Raise the loader arms to give access to the lift ram pivot pins

C

. The loader arms must be supported, use a tool as shown.

!

DANGER

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

3

Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.

Note:

If a hose burst protection valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

4

Label and then remove the lift ram hoses

A

. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

5

Fasten lifting straps to the lift ram, make sure that the weight of the ram is supported by the sling.

6

Remove pivot pin retaining bolt

B

and then remove the pivot pin

C

.

7

Remove pivot pin retaining bolt

D

.

8

Remove klipring

E

and shim

F

from both sides of ram, use slide hammer kit (service tool 993/68100) to remove pivot pin

G

.

9

Remove the lift ram.

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

Coat pivot pins with anti-rust lubricant.

Make sure that the head of item

D

is on the engine side.

Coat mainframe bores with grease.

Assembly sequence for shim

F

and klipring:

1st shim

2nd ram

3rd shim (as required)

4th klipring

Pivot pins with M24 pin extractor hole

1st spacer

2nd ram

3rd shim (as required)

4th klipring

All klipring installations to have a maximum end float of

2mm (0.080in.)

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

76 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

76 — 1

Removal and Replacement

— Loader Shovel Ram

B

C

E

C

B

C

B

D

E

C

D

B

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

S266340

Issue 1

Section E

76 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

76 — 2

Removal and Replacement

— Loader Shovel Ram

Removal

!

WARNING

The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a ‘scissor’ point with the loader arm. Make sure the interlevers are securely blocked when working in the loader arm area.

BF 2-1

1

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

2

Rest the shovel flat on the ground.

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

DANGER

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

3

Switch off the engine and vent residual hydraulic pressure from the loader end by operating the loader controls back and forth several times.

4

Label and then remove the shovel ram hoses

A

. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

5

Fasten lifting straps to the shovel ram, make sure that the weight of the ram is supported by the sling.

6

Remove kliprings

B

, shims

C

and spacers

D

.

7

Remove pivot pins

E

.

Coat pivot pins with anti-rust lubricant.

All klipring intallations to have a maximum end float of 2mm

(0.080in.)

Make sure that each klipring is installed with a shim.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

77 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

77 — 1

Removal and Replacement

— Slew Ram

1

Y

3

7

10

2

2A

6

9803/3280

4

5

Purchased from www.WorkshopManuals.co.uk

9

8

10

S254901

Issue 1

Section E

77 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

77 — 2

Removal and Replacement

— Slew Ram

Removal

1

Slew the backhoe to the left to remove the right hand slew ram and visa versa.

2

Lower the bucket to the ground and switch off the engine.

!

WARNING

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

3

Vent any residual hydraulic pressure by operating the backhoe and slew control levers.

4

Disconnect the hydraulic hoses

1

to the slew rams before disconnecting the hoses make sure that they are labelled (to assist with reassembly).

5

Plug and cap all open hydraulic connections to prevent ingress of dirt and loss of hydraulic fluid.

6

Loosen and remove trunnion bracket retaining nuts

2

and hardened washers

2A

(see note).

Note:

On assembly, the correct grade of nut (grade 12) and bolt (grade 10.9) must be used. Also, use hardened washers

2A —

NOT ordinary washers. Using incorrect specification items could result in a reduction of clamping efficiency.

7

Remove the trunnion bracket

3

.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

8

Attach suitable lifting straps to the slew ram assembly.

Note that the weight of the slew ram assembly is approximately 44 kg (97 lbs).

9

Remove thin nuts

4

( 2 off per pivot pin) and remove the pivot pin retaining bolt

5

. Use a 25 — 30 mm diameter bar to knock the pin out vertically.

10

Remove the slew ram (eye end) pivot pin

6

and swing the ram to clear the kingpost casting.

11

Lift the slew ram assembly clear of the machine.

Inspection

Inspect the liner bearings

7

(located in the trunnion retaining bracket

3

) and liner bearing

8

for signs of damage, wear, scores or nicks etc. Replace as required.

To remove the liner bearing

8

use a jack located against blanking plate

9

. Shown in the inset at

Y

.

To remove the bearing liner

7

from the trunnion bracket use flat faced bearing pullers.

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 immediately.

INT-3-1-10/1

Replacement is generally a reversal of the removal procedures, however note the following:

The liner bearings

7

and

8

have a ‘lead-in’ diameter

(noticeable with a slight step), always install the smaller diameter first into the pivot bore. The bearings must be installed so that they sit flush.

The eye end pivot pins

6

should be secured first — i.e.

BEFORE the trunnion bracket retaining nuts

2

, this will help to maximise ram assembly alignment.

Make sure that the hydraulic hoses are correctly installed.

Make sure that any new or reused bearings are clean and smeared with grease prior to reassembly of pins and trunnion journals.

When fully assembled, apply grease at each grease nipple

BEFORE operating the machine.

Torque Setting

Item Nm

2

650

lb ft

480

kgf m

66.3

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

78 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

78 — 1

L

L

H

E

G

F

G

E

C

B

A

D

9803/3280

Purchased from www.WorkshopManuals.co.uk

S271860

Issue 1

Section E

78 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

78 — 2

Removal and Replacement

— Stabiliser Ram (Sideshift)

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground.

2

Lo w er t he st ab iliser leg s unt il t he p ad s are approximately 4 in. (100mm) off the ground and stop the engine.

3

Remove the bottom locking nut

A

and bolt

B

. Drive out the bottom pivot pin

C

and allow the stabiliser foot

D

to fall clear. Lift the inner leg and temporarily refit the pivot pin

C

through inner leg and ram.

4

Place a block of wood underneath the stabiliser leg.

5

Remove circlips

E

and drive out top pivot pin

F

with spacing collars

G

.

6

Start the engine and slowly extend the stabiliser ram so that the dump end of the ram protrudes from the top of the outer leg section.

7

Attach suitable lifting gear to the ram as shown at

H

.

Make sure that the weight of the ram is supported by the sling and remove the bottom pivot pin

C

.

DANGER

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

8

Make sure the engine is switched off, vent residual hyd raulic p ressure b y m o ving t he b ac k ho e and stabiliser control levers back and forth.

Note:

If a check valve is fitted on the ram, the system will not vent . Ex t rem e c aut io n m ust b e used w hen releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

9

Loosen and remove the stabiliser hoses

L

, label the hoses before removing (as an aid to assembly). Plug all open orifices to prevent loss of fluid and ingress of dirt.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

Use suitable lifting appliances to locate the stabiliser ram.

After replacing or fitting the ram, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.

10

Using suitable lifting equipment, lift the ram clear.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

78 — 3

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

78 — 3

Removal and Replacement

— Stabiliser Ram (Centremount)

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the stabiliser legs to the ground.

2

Lower the backhoe and loader end to the ground and stop the engine.

DANGER

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

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

Use suitable lifting appliances to locate the stabiliser ram.

After replacing or fitting the ram, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.

3

Make sure the engine is switched off, vent residual hyd raulic p ressure b y m o ving t he b ac k ho e and stabiliser control levers back and forth.

Note:

If a check valve is fitted on the ram, the system will not vent . Ex t rem e c aut io n m ust b e used w hen releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

4

Carefully disconnect hydraulic hoses

A

and

B

from the st ab iliser hyd raulic ram , lab el t he ho ses b ef o re rem o ving (as an aid t o assem b ly). Release t he connections slowly.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

5

Wrap a suitable sling around the stabiliser ram, make sure that the weight of the ram is supported by the sling.

6

Remove the ram pivot pin retaining nut and bolt, drive out the ram pivot pin as shown at

C

.

7

Remove the stabiliser ram.

C

S263080

A

B

S261790

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

79 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

79 — 1

Removal and Replacement

— Dipper Ram

C

B

D

A

B

D

C

S266350

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

79 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

79 — 2

Removal and Replacement

— Dipper Ram

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and stop the engine.

DANGER

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

2

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.

Note:

If a hose burst protection valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

3

Label and then remove the dipper ram hoses

A

. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

4

Fasten lifting straps to the dipper ram, make sure that the weight of the ram is supported by the sling.

5

Remove t he p ivot p in ret aining nut

B

and b olt

C

, remove the pivot pin

D

.

6

Remove dipper ram.

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

80 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

80 — 1

Removal and Replacement

— Bucket Crowd Ram

B

C

D

A

C

D

B

S266360

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

80 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

80 — 2

Removal and Replacement

— Bucket Crowd Ram

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and stop the engine.

DANGER

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

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

2

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.

Note:

If a hose burst protection valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

3

Label and then remove the bucket crowd ram hoses

A

.

Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

4

Fasten lifting straps to the bucket crowd ram, make sure that the weight of the ram is supported by the sling.

5

Remove t he p ivot p in ret aining nut

B

and b olt

C

, remove the pivot pin

D

.

6

Remove the bucket crowd ram.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

81 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

81 — 1

Removal and Replacement

— Boom Ram

B

C

A

E

G

H

F

D

S266370

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

81 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

81 — 2

Removal and Replacement

— Boom Ram

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and stop the engine.

2

Remove pivot pin retaining nut

A

and bolt

B

. Remove the pivot pin

C

.

3

Remove the grease nipple from the eye end of the ram

(through access hole

D

).

4

Use the machine hydraulics to SLOWLY retract the ram.

5

Remove the hose clamp.

DANGER

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

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

It will be necessary to extend the ram to align and engage the boom pivot pin

C

. As the ram extends, the ram will tend to turn.

For this reason it is recommended that a smaller diameter steel bar is used to locate the boom ram at the kingpost casting. The steel bar can be more readily removed to allow for re-alignment of the boom pivot pin

C

.

When the boom pivot pin has been correctly aligned and fitted, then fit the correct pivot pin

H

at the kingpost.

6

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.

Note:

If a hose burst protection valve is fitted on the ram, the system will not vent. Extreme caution must be used when releasing hydraulic connections — release the connections one turn and allow the pressure to dissipate.

7

Label and then remove the boom ram hoses

E

. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

!

CAUTION

This component is heavy. Do not attempt to remove it unless its weight is held by a sling. Make sure that the sling is attached to a suitable lifting appliance.

HYD 2-3/1

8

Fasten lifting straps to the boom ram, make sure that the weight of the ram is supported by the sling.

9

Remove the pivot pin retaining nut

F

and bolt

G

remove the kingpost pivot pin

H

.

10

Remove the boom ram.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section E

85 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

85 — 1

20

14

15

16

8

7

13

5

4

4

3

9 1

11

10

19

18

17

6

12

s263650

2

7

6

5

4

3

9

1

11

10

9803/3280

TYPICAL RAM ASSEMBLY

Note that on boom and bucket rams, pivot pin grease seals are fitted.

Purchased from www.WorkshopManuals.co.uk

A263680

Issue 1

Section E

85 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

85 — 2

Dismantling and Assembly

— Loader Lift Ram

— Loader Shovel Ram

— Boom Ram

— Bucket Ram

— Stabiliser Ram

Dismantling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Place ram assembly on a locally manufactured strip/rebuild bench as shown.

S263670

Slacken end cap

1

using special spanner (see

Service

Tools)

, and remove the piston rod assembly

2

from the cylinder.

!

WARNING

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted.

Severe injury can be caused by a suddenly released piston rod.

HYD 1-2

Position piston rod assembly on bench in place of ram cylinder. Remove seal

4

and wear rings

3

and

5

from piston head.

Extract dowel

6

from the piston head using a metric screw

(M3, M4, or M6 depending on ram size) threaded into the extractor hole.

Remove piston head from rod using special spanner (see

Service Tools

).

Remove gland bearing and end cap

1

from piston rod and remove the ‘O’ ring

9

, wiper seal

10

and rod seal

11

. Check t he end c ap b earing f o r d am ag e, sc o res o r nic k s. If damaged, the bearing must be replaced as part of the end cap assembly.

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

Check the bore of the ram cylinder for damage.

Assembly

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying

JCB Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High

Strength).

Refer to

JCB Ram Sealing Procedure

for the correct method of fitting seals to the end cap and piston head.

Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into c ont ac t w it h t he JCB Thread loc ker and Sealer (High

Strength).

Note:

Neit her t he JCB Thread loc ker and Sealer (High

Strength) nor Activator must be allowed to contact seals, bearing rings, or ‘O’ rings.

Fit locking dowel

6

to piston head/rod as follows:

1

Fit ‘O’ ring

8

into piston head

7

.

2

Fit piston head to piston rod and torque tighten to 405

Nm (300 lbf ft).

3

New ram Shaft and piston head fitted.

— If both are required, the following procedure should be followed:

a

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit; refer to the table for drill diameters and depths.

b

Remove all swarf and contamination. Insert dowel

6

into drilled hole, make sure tapped extractor hole is to outside.

4

New piston head fitted on a

pre-drilled piston rod.

Re- drill and dowel

BOTH

the piston head and piston rod at 90° from the existing drilled dowel hole in t he p ist on rod . Follow t he p roc ed ures described in step 3.

5

New piston rod fitted to a

pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head.

a

Use a drill the same diameter as the pre-drilled hole in the piston head to make a ‘centre mark’ in the piston rod. DO NOT drill the piston rod at this stage.

………..continued

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

85 — 3

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

85 — 3

Dismantling and Assembly:

— Loader Lift Ram

— Loader Shovel Ram

— Boom Ram

— Bucket Ram

— Stabiliser Ram

Assembly (continued)

DRILLING DETAILS FOR PISTON HEAD RETENTION b

Use an undersized diameter drill as a guide and drill into the piston rod to the required depth (see table), make sure the drill has centred correctly on the

‘centre mark’ made at step 5a.

c

Use the correct size diameter drill to suit the dowel and drill to the required depth (see table).

d

Remove all swarf and contamination, insert the dowel.

Position cylinder on bench and install rod assembly into cylinder.

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the end cap to 678

Nm (500 lbf ft).

Note:

If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result . Cure t im es vary ac c o rd ing t o t he am b ient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Note:

Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

Torque Settings

Item

7

1

Nm

405

678 kgf m lbf ft

41.3

300

69.2

500

Y

X

A263750

(all dimensions in mm)

Size

80 x 50

70 x 40

Size

6Ø x 20

Drill Ø

Guide Dowel

Drill

Depth

Drill Ø X Drill

Depth Y

4 21 6.02/6.10

22/23

90 x 50 8Ø x 25

100 x 60

5

110 x 60 12Ø x 30 8

110 x 65

120 x 65 12Ø x 35 8

130 x 75

24

28

33

8.02/8.10

27/28

12.02/12.10 32/33

12.02/12.10 37/38

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

86 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

86 — 1

19

20

6

7

8

5

4

22

21

3

9

10

11

12

16

7

6

5

4

3

8

2

1

18

14

13

11

12

1

14

13

17

15

S263740

9803/3280

Purchased from www.WorkshopManuals.co.uk

S263730

Issue 1

Section E

86 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

86 — 2

Dismantling and Assembly

— Dipper Ram

Dismantling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Place ram assembly on a locally manufactured strip/rebuild bench as shown.

S263670

Slacken end cap

1

using special spanner (see

Service

Tools

), and remove the piston rod assembly

2

from the cylinder.

!

WARNING

If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely fitted.

Severe injury can be caused by a suddenly released piston rod.

HYD 1-2

Position piston rod assembly on bench in place of ram cylinder. Remove seal

4

and wear rings

3

and

5

from piston head.

Extract dowel

6

from the piston head using a metric screw

(M3, M4, or M6 depending on ram size) threaded into the extractor hole.

Remove piston head from rod using special spanner (see

Service Tools

).

Remove gland bearing and end cap

1

from piston rod and remove the ‘O’ rings

11

and

12

, wiper seal

13

and rod seal

14

. Check the end cap bearing for damage, scores or nicks.

If damaged, the bearing must be replaced as part of the end cap assembly.

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

Check the bore of the ram cylinder for damage.

Assembly

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying

JCB Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High

Strength).

Refer to

JCB Ram Sealing Procedure

for the correct method of fitting seals to the end cap and piston head.

Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into c ont ac t w it h t he JCB Thread loc ker and Sealer (High

Strength).

Note:

Neit her t he JCB Thread loc ker and Sealer (High

Strength) nor Activator must be allowed to contact seals, bearing rings, or ‘O’ rings.

Ensure that end damping spring

9

is engaged with collar

10

and piston head

7

.

Fit locking dowel

6

to piston head/rod as follows:

1

Fit ‘O’ ring

8

into piston head

7

.

2

Fit piston head to piston rod and torque tighten to 405

Nm (300 lbf ft).

3

New ram Shaft and piston head fitted.

— If both are required, the following procedure should be followed:

a

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit; refer to the table for drill diameters and depths.

b

Remove all swarf and contamination. Insert dowel

6

into drilled hole, make sure tapped extractor hole is to outside.

4

New piston head fitted on a

pre-drilled piston rod.

Re- drill and dowel

BOTH

the piston head and piston rod at 90° from the existing drilled dowel hole in t he p ist on rod . Follow t he p roc ed ures described in step 3.

5

New piston rod fitted to a

pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head.

………..continued

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

86 — 3

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

86 — 3

Dismantling and Assembly:

— Dipper Ram

Assembly (continued) a

Use a drill the same diameter as the pre-drilled hole in the piston head to make a ‘centre mark’ in the piston rod. DO NOT drill the piston rod at this stage.

b

Use an undersized diameter drill as a guide and drill into the piston rod to the required depth (see table), make sure the drill has centred correctly on the

‘centre mark’ made at step 5a.

c

Use the correct size diameter drill to suit the dowel and drill to the required depth (see table).

d

Remove all swarf and contamination, insert the dowel.

Position cylinder on bench and install rod assembly into cylinder.

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the end cap to 678

Nm (500 lbf ft).

Note:

If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result . Cure t im es vary ac c o rd ing t o t he am b ient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Note:

Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

Torque Settings

Item

7

1

Nm

405

678 kgf m lbf ft

41.3

69.2

300

500

DRILLING DETAILS FOR PISTON HEAD RETENTION

Y

X

A263750

(all dimensions in mm)

Size

80 x 50

70 x 40

Size

6Ø x 20

Drill Ø

Guide Dowel

Drill

Depth

Drill Ø X Drill

Depth Y

4 21 6.02/6.10

22/23

90 x 50 8Ø x 25

100 x 60

5

110 x 60 12Ø x 30 8

110 x 65

120 x 65 12Ø x 35 8

130 x 75

24

28

33

8.02/8.10

27/28

12.02/12.10 32/33

12.02/12.10 37/38

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

87 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

2

Section E

87 — 1

3 4

5

1

6

10

9

8

7

11

16

15

12

14

13A

13

15

16

14

17

18

19

20

S263690

22

21

9803/3280

13

6

12

9

8

7

Purchased from www.WorkshopManuals.co.uk

S263710

2

Issue 1

Section E

87 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

87 — 2

Dismantling and Assembly

— Slew Ram

Dismantling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Place ram assembly on a locally manufactured strip/rebuild bench as shown, or alternatively, hold the ram in a suitable vice taking care not to damage machined faces.

Remove cylinder

6

using special spanner (see

Service

Tools

). Tap the cylinder off the piston head assembly using a suitable drift (e.g. nylon).

Position the piston rod assembly in a vice, use soft jaws and stand the assembly vertical whilst clamping on the eye end.

S266380

Remove seal

8

and wear rings

7

and

9

from piston head.

Extract dowel

10

from the piston head using a metric screw threaded into the extractor hole.

Remove piston head from rod using special spanner (see

Service Tools

).

Remove ‘O’ ring

12

.

Lift the end cap assembly

13

off the piston rod. Remove ‘O’ ring

14

, rod wiper seal

15

and rod seal

16

from the end cap assembly. Check the end cap bearing

13A

for damage, scores or nicks.

Item

18

is the metering orifice plate and item

17

its retaining wire, do not remove these items unless problems with the metering are suspected.

Ensure that metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the seals.

Check the bore of the ram cylinder for damage.

Assembly

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying

JCB Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and Sealer (High

Strength).

Refer to

JCB Ram Sealing Procedure

for the correct method of fitting seals to the end cap and piston head.

Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into c ont ac t w it h t he JCB Thread loc ker and Sealer (High

Strength).

Note:

Neit her t he JCB Thread loc ker and Sealer (High

Strength) nor Activator must be allowed to contact seals, bearing rings, or ‘O’ rings.

Fit locking dowel

10

to piston head/rod as follows:

1

Fit ‘O’ ring

12

into piston head

11

.

2

Fit piston head to piston rod and torque tighten to 405

Nm (300 lbf ft).

3

New ram Shaft and piston head fitted.

— If both are required, the following procedure should be followed:

a

Drill through piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit; refer to the table for drill diameters and depths.

b

Remove all swarf and contamination. Insert dowel

10

into drilled hole, make sure tapped extractor hole is to outside.

4

New piston head fitted on a

pre-drilled piston rod.

Re- drill and dowel

BOTH

the piston head and piston rod at 90° from the existing drilled dowel hole in t he p ist on rod . Follow t he p roc ed ures described in step 3.

5

New piston rod fitted to a

pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head.

a

Use a drill the same diameter as the pre-drilled hole in the piston head to make a ‘centre mark’ in the piston rod. DO NOT drill the piston rod at this stage.

………..continued

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

87 — 3

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

87 — 3

Dismantling and Assembly

— Slew Ram

Assembling (continued) b

Use an undersized diameter drill as a guide and drill into the piston rod to the required depth (see table), make sure the drill has centred correctly on the

‘centre mark’ made at step 5a.

c

Use the correct size diameter drill to suit the dowel and drill to the required depth (see table).

d

Remove all swarf and contamination, insert the dowel.

Install cylinder onto the rod assembly, make sure that the cylinder is fitted square to the rod assembly. Firmly push the cylinder over the piston head seals.

Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the cylinder to 678

Nm (500 lbf ft).

Note:

If hydraulic oil contacts the uncured JCB Threadlocker and Sealer (High Strength) a weakening of the bond will result . Cure t im es vary ac c o rd ing t o t he am b ient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Note:

Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.

Position pipe assembly in correct position and torque tighten probe assembly

2

to 75Nm (55 lbf ft; 7.6 kgf m). DO NOT over-tighten the probe.

Make sure seals

19

and

21

are fitted the correct way as shown.

Torque Settings

Item Nm

11

6

405

678 kgf m lbf ft

41.3

300

69.2

500

DRILLING DETAILS FOR PISTON HEAD RETENTION

Y

X

A263750

(all dimensions in mm)

Size

80 x 50

70 x 40

Size

6Ø x 20

Drill Ø

Guide Dowel

Drill

Depth

Drill Ø X Drill

Depth Y

4 21 6.02/6.10

22/23

90 x 50 8Ø x 25

100 x 60

5

110 x 60 12Ø x 30 8

110 x 65

120 x 65 12Ø x 35 8

130 x 75

24

28

33

8.02/8.10

27/28

12.02/12.10 32/33

12.02/12.10 37/38

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

88 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

A

Section E

88 — 1

1

A258580

5

4

B

7

8

6

A258590

8

3

2

D

2

C

7

8

1

4

4

1

6

5

8

6

8

7

8

9803/3280

5

Purchased from www.WorkshopManuals.co.uk

2

3

322580

2

A326710

Issue 1

Section E

88 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

88 — 2

Dismantling and Assembly

— Power Sideshift Ram

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Dismantling

1

Fix the ram assembly on a locally manufactured strip/rebuild bench as shown at

A

.

2

Remove both end caps

1

, (46mm AF). Pull the piston rod assembly from the cylinder.

Note 1:

DO NOT allow the piston rod to come into contact with the cylinder bore. The cylinder bore may be damaged by careless dismantling.

3

Position the piston rod assembly on a bench in place of the ram cylinder. Remove the wear rings

2

and seal

3

from the piston head.

Note 2:

The piston head cannot be removed from the rod. If there is damage to the rod or piston head, replace the complete assembly.

4

Carefully inspect the bore of the cylinder and the piston rod outer diameter for scoring, nicks and burrs. If such damage is visible the components must be renewed.

Note 3:

If burrs are evident on the ends of the piston rod at positions

C

or

D

remove by careful filing.

5

Remove the end cap seal

4

, wiper seal

5

and ‘O’ ring

6

, both end caps are the same

6

Remove spacers

7

and ‘O’ rings

8

.

Assembly

1

Clean the threads of the end caps and cylinder using a wire brush.

2

Use JCB Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant. Allow 15 minutes for solvent to dry before applying JCB

Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and

Sealer (High Strength).

3

Refer to

JCB Ram Sealing Procedure

for the correct method of fitting seals to the end cap and piston head.

4

Clamp the cylinder vertically and lower the piston rod assembly in from the top, as shown at

B

. Take care not to allow the piston rod to come into contact with the cylinder bore. Be sure to engage the piston head new wear rings and seal carefully into the cylinder. If the piston head wear rings or seal are damaged during this stage, they must be renewed.

5

Fit new ‘O’ rings

8

to spacers

7

, slide onto the piston head and rod assembly.

6

Apply JCB Activator to threads of the end caps and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and

Sealer (High Strength).

Note 4:

Neither the JCB Threadlocker and Sealer (High

Strength) nor Activator must be allowed to contact seals, bearing rings or ‘O’ rings.

7

Apply JCB Threadlocker and Sealer (High Strength) to threads of the ends caps, fit new ‘O’ rings

6

.

8

Ensure that there are no burrs at the ends of the piston rod, see

Dismantling — Note 3:

9

Fit an end cap over the piston rod. Apply light hand pressure to the cap to engage the gland seal on the piston rod. DO NOT use excessive force. Screw on the first end cap and then fix the assembly on the strip/rebuild bench as shown at

A

. Fit the remaining cap and then torque tighten both caps.

Note 5:

If hydraulic oil contacts the uncured JCB

Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Torque Settings

Item

1

Nm

400

kgf m lbf ft

40.8

295

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

89 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

89 — 1

JCB Ram Sealing Procedure

To fit new rod seal:

Use seal fitting tool (892/00334) to fit rod seals, the size

(diameter) and position of pins

A

is determined by the diameter and radial width of the rod seal being fitted.

The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals.

1

Open the tool as shown at

B

and insert the new rod seal, the seal must be fitted behind the two front pins but in front of the rear pin as shown.

Note

: Make sure the seals are fitted the correct way round, as shown at

P

and

Q

.

2

Close the tool as shown at

C

. The seal must form a reniform (kidney shape).

3

Before fitting the rod seals check the seal grooves are free of contamination and sharp edges,

4

Locate the seal in the end cap groove, shown at

D,

when the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its groove and remove the tool.

5

Fit rod wiper seal

P

into seal groove. Make sure the seal is correctly installed as shown.

Note

: Some rod wipers, ie power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to ensure the seal is square before it is pressed in.

Sleeve

E

must be used to protect the rod seals from damage when fitting end cap onto the piston rod. There are various sizes of sleeve, see

Service Tools

. Make sure the hexagon on the end cap is towards the eye end of the rod.

B

C

P

Q

A

D

161750

153212

E

A187361

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

89 — 2

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Rams

Section E

89 — 2

JCB Ram Sealing Procedure (continued)

Fit new piston head seals:

6

Use a blunt instrument (892/01027) shown at

F

, lever the inner seal

G

into the piston head seal groove, do not let the seal twist. There are identification marks on the outer diameter of the seal, make sure the marks are visible and the seal is free to rotate, if not remove the seal and refit

7

Fit outer seal

H

using the same procedure as step 6.

Check the external grooves are visible.

8

Ensure O ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the relevant section for torque figure and completion of ram assembly.

9

Fit the piston head retaining dowel, see ram dismantling and assembling relevant section

10

Fit wear rings

J

and

K

. Rotate the wear rings so that the piston retention dowel is covered by the wear ring, NOT as shown at

L

.

Fit the piston rod and head assembly into the cylinder:

11

Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.

12

Fit the end cap, refer to the relevant section for torque figure and completion of ram assembly.

F

G

H

338470

338480

J

K

L

338490

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section E

95 — 1

www.WorkshopManuals.co.uk

Hydraulics

Hydraulic Oil Cooler

Section E

95 — 1

Removal and Replacement

!

WARNING

Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

GEN 3-2

!

DANGER

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

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and stop the engine.

2

Vent residual hydraulic pressure by operating the controls back and forth several times.

3

Label and then remove hydraulic hoses

A

and

B

(see note). Plug and cap all open ports to prevent loss of fluid and ingress of dirt.

Note:

When installing and removing hoses from the cooler, it is essential to note that adaptor

C

must be held with a spanner whilst installing or removing the hose. It may be easier to remove the top hose connection once the cooler has been removed from the machine (disconnect top hose at connection

D

).

4

Loosen and remove cooler mounting bolts

E

(4 off) and remove the cooler

F

.

Replacement

Replacement is a reversal of the removal sequence.

!

WARNING

Fine je t s of hydra ulic fluid a t high pre ssure c a n 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.

INT-3-1-10/1

When installing and removing hoses from the cooler, it is essential to note that adaptor

C

must be held with a spanner whilst installing or removing the hose. Tighten hose connections to a torque of 58 Nm (42 lbf ft).

C

A

E

A

F

B

E

B

A401100

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section E

96 — 1

www.WorkshopManuals.co.uk

Hydraulics

Smooth Ride System

Section E

96 — 1

Accumulator

Removal and Replacement

Removal

1

Park the machine on level ground, lower the loader arms, switch off the engine and chock all four wheels.

Release all hydraulic pressure in the accumulator by selecting the SRS ON and operating the loader arm hydraulic lever.

!

DANGER

Before disconnecting or dismantling the accumulator discharge all gas pressure. Failure to comply can cause rapid discharge of gas and/or hydraulic fluid which can result in death, personal injury and damage to the machine.

Hyd 2-5

2

Discharge the accumulator, refer to

Service

Procedures, Smooth Ride System —

Charging/Discharging the Accumulator

.

3

Disconnect hydraulic hose

A

and plug.

4

Loosen both ‘U’ clamps

B

and slide the accumulator towards the front of the machine. When clear of the ‘U’ clamps carefully lower and withdraw accumulator.

Replacement

Replacement is a reverse of removal.

1

Charge the accumulator, refer to

Service Procedures,

Smooth Ride System — Charging/ Discharging the

Accumulator

.

2

Operate the machines hydraulic system. Check for correct operation and leaks.

3

Replenish the hydraulic system with the recommended hydraulic fluid as required, refer to Section 3

Fluids,

Lubricants, Capacities and Specifications.

9803/3280

B

Purchased from www.WorkshopManuals.co.uk

B

A

S308290

Issue 1

Section E

96 — 2

www.WorkshopManuals.co.uk

Hydraulics

Smooth Ride System

Section E

96 — 2

10 9 10

8 7

7

A

1

7

8

7

A

5

7

8

9803/3280

6

11

10

9

10

11

8

7

4

13

12

3

2

Purchased from www.WorkshopManuals.co.uk

S308280

Issue 1

Section E

96 — 3

www.WorkshopManuals.co.uk

Hydraulics

Smooth Ride System

Section E

96 — 3

Accumulator

Dismantling and Assembly

Dismantling

!

DANGER

Before disconnecting or dismantling the accumulator discharge all gas pressure. Failure to comply can cause rapid discharge of gas and/or hydraulic fluid which can result in death, personal injury and damage to the machine.

HYD 2-5

1

Check that the accumulator has been discharged, refer to

Service Procedures, Smooth Ride System —

Charging/Discharging the Accumulator

.

2

Secure the accumulator in horizontal position.

!

CAUTION

The gas end cap (cap with gas valve) must be removed before the hydraulic end cap. This allows any residual pressure to escape through the safety vent holes. If the hydraulic end cap is removed first the piston will cover the safety vent holes, which could result in the piston being forced out under pressure which may result in personal injury.

HYD 2-6

3

Fit three pins into the holes in gas end cap

4

, using a long bar working against the pins unscrew the end cap.

4

Fit three pins into the holes in hydraulic end cap

5

, using a long bar working against the pins unscrew the end cap.

5

Remove and discard ‘O’ rings and back up rings from end caps.

6

Remove the piston

6

by pushing from the hydraulic end with a bar.

!

CAUTION

Do not remove the piston by applying compressed air at the opposite end.

HYD 2-7

7

Remove piston seal and ‘O’ rings.

Inspection

Inspect piston for cracks, burrs around the ‘O’ ring grooves, or damage. Examine the body bore

1

, using a light, for scratches or scoring. Inspect end caps for damaged threads or burrs on ‘O’ ring grooves.

Minor nicks, scratches or light scoring of the body bore may be removed by using a very fine paper. Dress the bore until all apparent imperfections have been removed.

All seals and ‘O’ rings must discarded and new ones fitted.

Assembly

1

Coat all internal components with clean hydraulic oil.

2

Fit piston seal

9

, teflon back up rings

10

and seals

11

.

3

Fit piston assembly into bore

1

with hollow side towards the gas end. Do not let piston seal drag on threads, the piston must go into the bore exactly square and very slowly. The piston is a tight fit, use a hammer and a block of wood to tap the piston until all of the piston is 2in. (50mm) below the beginning of honed bore.

Note

: Keep pressure on the piston while tapping through the bore chamfer, otherwise the piston will bounce back, damaging the piston ring.

4

Fit end cap back up seal

7

. Make sure the seal is fitted with leading edge

A

pointing in a counter clockwise direction otherwise the seal will bind when the end cap is fitted.

5

Fit end cap ‘O’ rings

8

, it is important that seals

7

and

8

are fitted in the correct position in relation to each other to prevent leaks.

6

Fit end caps

4

and

5

, use pins and a long bar. Make sure the gas end cap is fitted to the correct end, piston hollow end to gas side.

Note

: The end caps will stop against the chamfer leading into the honed bore, ‘O’ ring sealing is not dependent upon cap tightness.

7

Use new ‘O’ ring

13

and fit the gas valve

12

.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

i

Section F

www.WorkshopManuals.co.uk

Transmission

Contents Page No.

Section F i

Service Tools

Technical Data

Wheels and Tyres

Axles

Synchro Shuttle Gearbox

Powershift Gearbox — 6 Speed

Powershift Gearbox — 4 Speed

Engine Stall Speed Combinations

Basic Operation

Axles

Synchro Shuttle Gearbox

Component Identification

Principle of Operation

Hydraulic and Electrical Operation

Powershift Gearbox

Component Identification

Principle of Operation

Hydraulic and Electrical Operation

ShiftMaster Operation Characteristics

Drive Paths — 4 Speed

Drive Paths — 6 Speed

Torque Converter

Component Identification

Principle of Operation

Systems Description

Synchro Shuttle Gearbox

Syncromesh (Blocking Pin Type)

Forward/Reverse Clutch Operation

*

*

2/4 Wheel Drive Clutch Operation

— Pressure ON/Spring OFF Type

— Spring ON/Pressure OFF Type

Powershift Gearbox

Clutch Operation — Forward, Reverse

Clutch Operation — Mainshaft, Layshaft, 6 Speed

Clutch Operation — 2/4 Wheel Drive

Electrical Connections

Powershift Gearbox — 4 Speed

Powershift Gearbox — 6 Speed (ShiftMaster)

Fault Finding

Synchro Shuttle Gearbox

2/4 Wheel Drive Clutch

Powershift Gearbox

1 — 1

15 — 1

16 — 2

16 — 2

16 — 4

17 — 2

17 — 2

17 — 4

17 — 5

18 — 1

18 — 5

2 — 1

3 — 1

4 — 1

5 — 1

6 — 1

7 — 1

20 — 1

20 — 1

25 — 2

26 — 1

27 — 1

27 — 3

30 — 1

30 — 1

30 — 1

32 — 1

33 — 1

35 — 1

36 — 1

40 — 1

Continued…

9803/3280 Issue 3*

Purchased from www.WorkshopManuals.co.uk

ii

Section F

www.WorkshopManuals.co.uk

Transmission

Section F ii

Contents Page No.

Service Procedures

Front Axle — SD55, SD70

Renewing the Pinion Oil Seal

Rear Axle — SD80, PD70

Renewing the Pinion Oil Seal

Brakes — Testing for Piston Seal Leakage

Synchro Shuttle Gearbox

Stall Test

Pressure and Flow Tests

Forward/Reverse Solenoid Control Valve

Dismantling and Assembly

Powershift Gearbox

*

Gearbox Hydraulic Pump

Removal and Replacement

*

Suction Strainer

Removal and Replacement

*

*

Stall Test

Pressure and Flow Tests

Speed Sensor — Testing

ShiftMaster

Electronic Control Unit

Diagnostics User Guide

Diagnostics Troubleshooting Guide

Propshafts

Removal and Replacement

Front Axle – SD 55/SD70

Removal and Replacement

Hub and Driveshaft

Dismantling and Assembly

Drivehead – SD55

Dismantling and Assembly

Drivehead – SD70

Dismantling and Assembly

Crownwheel and Pinion Meshing

Front Axle —

(2 wheel drive machines)

Removal and Replacement

Dismantling and Assembly

75 — 1

80 — 1

81 — 1

82 — 1

83 — 1

83 — 8

85 — 1

86 — 1

63 — 1

64 — 1

65 — 1

66 — 1

67 — 1

68 — 1

69 — 1

70 — 1

50 — 1

51 — 1

52 — 1

55 — 2

55 — 2

57 — 1

Continued…

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

iii

Section F

www.WorkshopManuals.co.uk

Transmission

Contents Page No.

Section F

iii

Rear Axle – PD70, SD80

Removal and Replacement

Brakes

Dismantling and Assembly

Hub and Driveshaft — SD80

Dismantling and Assembly

Hub and Driveshaft — PD70

Dismantling and Assembly

Drivehead

Dismantling and Assembly

Crownwheel and Pinion Meshing

Axles

Collapsible Spacer

Limited Slip Differential

Dismantling and Assembly

95 — 1

100 — 1

Synchro Shuttle Gearbox

Removal and Replacement

Dismantling

Inspection

105 — 1

110 — 1

111 — 1

112 — 1 Assembly

Clutch Dismantling and Assembly Procedures

Forward/Reverse Clutch

2/4 Wheel Drive Clutch (4WD Pressure On)

113 — 1

114 — 1

2/4 Wheel Drive Clutch (4WD Pressure Spring On) 115 — 1

2/4 Wheel Drive Clutch Pressure Testing 116 — 1

Piston Ring Seals — Fitting Procedure 117 — 1

Powershift Gearbox

Removal and Replacement

Dismantling

Inspection

Assembly

Clutch Dismantling and Assembly Procedures

Forward/Input and Reverser Clutch

Layshaft Clutch

Mainshaft Clutch

6 Speed Clutch

2/4 Wheel Drive Clutch

Piston Ring Seals — Fitting Procedure

120 — 1

125 — 1

126 — 1

127 — 1

130 — 1

131 — 1

132 — 2

133 — 1

134 — 1

140 — 1

90 — 1

91 — 1

92 — 1

93 — 1

94 — 1

94 — 8

Torque Converter

Removal and Replacement 150 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

1 — 1

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 1

892/01077 Synchro Shuttle Gearbox — Selector

Shaft Lock Screw

892/01078 Synchro Shuttle Gearbox — Mainshaft

Adjuster

A395350

A396510

Synchro Shuttle Gearbox — Setting ring socket spanners

892/01079

(Mainshaft setting ring)

A396590

892/01080

(Layshaft setting ring)

A396600

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section 1

1 — 2

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section 1

1 — 2

Service Tools

(cont’d)

892/00179 Bearing Press (use with appropriate adapters)

892/00812 Drive Coupling Spanner

S188200

992/07608 Bearing Adapter

992/07609 Bearing Adapter

992/07610 Bearing Adapter

992/07611 Bearing Adapter

992/07612 Bearing Adapter

992/07613 Bearing Adapter

S188160

Powershift Gearbox Flow Test Adaptor

1

460/15708 Flow Test Adapter

2

460/15707 Banjo Bolt

3

2401/0222 O-ring

4

2403/0110 O-ring

5

2403/0108 O-ring

6

1604/0004 Adapter

7

1406/0018 Sealing Washer

892/00922 12.2” Torque Converter Alignment Tool

S107750

2

5

4

1

S267260

A

892/00920 Flow Test Adapter

B

892/00301 Flow Test Adapter

C

892/00302 Flow Test Adapter

7

6

3

A313250

S188210

A

B

C

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

1 — 3

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 3

892/00224

Impulse Extractor Set for Hub Bearing Seals

S261230

Torque Measuring Tool for Wheel Hub Seals

Manufacture locally, procedures in this manual show checking the wheel hub seal using a rolling force.

However, the torque can be measured using above locally manufactured tool.

Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft) excluding seal drag. Maximum permissible including seal drag is 40 Nm (29.5 lbf ft).

S197070

892/00891

Fitting Tool Assembly for

Wheel Hub Seals

S227760

892/00225

993/59500

Adapter — Impulse Extractor

Small 17mm to 25mm

Medium 25mm to 45mm

Large 45mm to 80mm

Adapter — Impulse Extractor (syncro shuttle and powershift transmission)

S216290

892/00817 17 mm A/F x 3/4in. square drive

892/00818 22 mm A/F x 3/4in. square drive

892/00819 15 mm A/F x 1/2in. square drive

892/00333 19 mm A/F x 3/4in. square drive

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

1 — 4

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 4

992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts)

S197030

992/04800

Flange Spanner — for locking brake disc flange while pinion nut is slackened or torque set

892/00174 Measuring Cup — Pinion Head Bearing

S190770

892/00822 Splined Bolt Socket for driveshafts

S197060

S197040

892/00182 Bearing Pad Driver

S216310

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

1 — 5

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 5

S267300

Hydraulic Circuit Pressure Test Kit (also used for main hydraulic system tests)

892/00253

:892/00201

:892/00202

:892/00203

:892/00254

993/69800

892/00706

Pressure Test Kit

Replacement Gauge 0-20 bar (0-300 lbf/in

2

Replacement Gauge 0-40 bar (0-600 lbf/in

2

Replacement Hose

Seal Kit for 892/00254 (can also be used with probe 892/00706)

Test Probe

)

)

Replacement Gauge 0-400 bar (0-6000 lbf/in

2

)

S188121

Flow Test Equipment (also used for main hydraulic system tests)

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 — 100 l/min (0 — 22 UK gal/min)

892/00293 Connector Pipe

892/00270 Load Valve

1406/0021 Bonded Washer

1604/0006 Adapter 3/4 in M x 3/4 in M BSP

1612/0006 Adapter 3/4 in F x 3/4 in M BSP

892/00271 Adapter 3/4 in F x 5/8 in M BSP

892/00272 Adapter 5/8 in F x 3/4 in M BSP

816/20008 Adapter 3/4 in F x 1/2 in M BSP

892/00275 Adapter 1/2 in F x 3/4 in M BSP

892/00276 Adapter 3/4 in F x 3/8 in M BSP

892/00277 Adapter 3/8 in F x 3/4 in M BSP

892/00273 Sensor Head 0 — 380 l/min

892/00294 Connector Pipe

1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078 Connector 1 in F x 1 in F BSP

1604/0008 Adapter 1 in M x 1 in M BSP

1606/0012 Adapter 1 in M x 3/4 in M BSP

816/20013 Adapter 3/4 in F x 1 in M BSP

S188151

S316250

Test Point

1 892/00964 Test point (1/8 BSP) Powershift

2 892/00965 Test point (3/8 BSP) Powershift

3 892/00966 Test point (1/4 BSP) Synchro Shuttle

These test points can be left in position after testing.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

1 — 6

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 6

1

5

A396960

6

2

A396930

7

3

A396950

4

9803/3280

A396580

Purchased from www.WorkshopManuals.co.uk

A396940

8, 9

Issue 2*

Section F

1 — 7

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 7

Service Tools

(cont’d)

Solid Spacer Setting Kit

Synchro Shuttle Gearbox, SD70, SD80

Axles

1

892/00918

2

921/52627

3

993/70111

4

892/01076

5

6

7

892/01075

997/11000

998/10567

Setting Tool Kit

Spacer 14.20 Service use

Breakback Torque Wrench

Support Bracket —

Synchro Shuttle Gearbox

Support Bracket

PD70, SD80 Rear Axles

Support Bracket

SD55, SD70 Front Axles

SD80 Pinion Shaft Adaptor

Spacer Kit — SD55 Axles

8

921/53300

Comprises of:

921/53322

921/53323

921/53324

921/53325

921/53301

921/53302

921/53303

921/53304

921/53305

921/53306

921/53307

921/53308

921/53309

921/53310

921/53311

921/53312

921/53313

921/53314

921/53315

921/53316

921/53317

921/53318

921/53319

921/53320

921/53321

Spacer thickness mm

13.550

13.575

13.600

13.625

13.650

13.675

13.700

13.725

13.750

13.775

13.800

13.825

13.850

13.875

13.900

13.925

13.950

13.975

14.000

14.025

14.050

14.075

14.100

14.125

14.150

9

921/53400 Spacer Kit — Sychro Shuttle Gearbox,

SD70, SD80 Axles

Comprises of:

921/52606

829/30413

921/52607

829/30414

921/52608

829/30415

921/52609

829/30416

921/52610

829/30417

921/52611

921/53424

921/53425

921/53426

921/53427

921/53428

921/52628

829/30405

921/52629

829/30406

921/52630

829/30407

921/52601

829/30408

921/52602

829/30409

921/52603

829/30410

921/52604

829/30411

921/52605

829/30412

921/53401

921/53402

921/53403

921/53404

921/53405

921/53406

921/53407

921/53408

921/53409

921/53410

921/53411

921/53412

921/53413

921/53414

921/53415

921/53416

921/53417

921/53418

921/53419

921/53420

921/53421

921/53422

921/53423

921/52626

Note:

After using a spacer, obtain a replacement to keep the set complete

Spacer thickness mm

13.000

13.025

13.050

13.075

13.100

13.125

13.150

13.175

13.200

13.225

13.250

13.275

13.300

13.325

13.350

13.375

12.600

12.625

12.650

12.675

12.700

12.725

12.750

12.775

12.800

12.825

12.850

12.875

12.900

12.925

12.950

12.975

13.400

13.425

13.450

13.475

13.500

13.525

13.550

13.575

13.600

13.625

13.650

13.675

13.700

13.725

13.750

13.775

13.800

13.825

13.850

13.875

13.900

13.925

13.950

14.000

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

*

Section F

1 — 8

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 8

Service Tools

(cont’d)

892/01083 Powershift — Assembly tool, transfer gear

892/01084 Powershift — Transfer gear, bearing assembly

892/01085 Powershift — Seal fitting tool

When removing the Powershift gearbox use of a special transmission jack is strongly recommended. This jack can also be used when removing Synchro Shuttle gearboxes.

Note that the jack must be used with special support plates, see the facing page for details.

A402680

*

823/10420 Thrust Washer Kit — Powershift gearbox — Layshaft clutch

Comprises of:

823/10421

823/10422

823/10423

823/10424

823/10425

823/10426

Washer thickness mm

4.3

4.4

4.5

4.6

4.7

4.8

*

892/01096 Speed Sensor Test Harness —

Powershift Gearbox

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section F

1 — 9

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 9

Service Tools

(cont’d)

*

Powershift gearbox — support plates for use with hydraulic jack. Plates should be locally manufactured from 5 mm thick mild steel plate.

Rear plate — 4 speed and 6 speed.

Front plate — 6 speed.

Front plate — 4 speed.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

1 — 10

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 10

Service Tools

(cont’d)

892/01082 Powershift — Assembly Cradle

Note:

Support legs will also be required. These must be locally manufactured so that the gearbox can be supported as shown at

A

.

R

125.0

9

325.0

620.0

151.9

111.6

30.0

171.6

103.4

20.0

13

49

2

R

121.0

48

60.7

153.2

R

137.0

9

R 5.0

TYP

20.0

R

109.0

R

62.0

25.0

TYP 9 PLACES

==

142.3

2.9

53.2

95.0

118.7

30

A402690

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

1 — 11

www.WorkshopManuals.co.uk

Transmission

Service Tools

Section F

1 — 11

Service Tools

(cont’d)

Powershift Gearbox — hydraulic pump removal tools

The tools detailed below enable the pump to be removed with the torque converter housing in place.

1

Reaction bar. Locally manufacture from mild steel bar.

Drill the 2 holes through the bar as shown.

2

2 off lengths of M10 x 1.5 threaded rod 250 mm (10 in) long.

3

2 off M10 x 1.5 nuts.

A set of M10 x 1.5 taps will also be required.

1

2

3

12 mm

32 mm

500 mm

121.5 mm

11.0 mm

A406000

Powershift Gearbox — 6 Speed (ShiftMaster)

Electronic Service Tool Kit

892/01033 Kit comprises:

1

Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable ShiftMaster diagnostics software.

1

2

Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types.

3

Interconnecting cable, DLA to machine ECU diagnostics socket.

4

Kit carrying case.

2

3

B

J

H

C

A

G

D

E

F

4

A406130

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

2 — 1

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

2 — 1

Tyre Pressures

Note:

If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

Front Wheels

AWS/4WD MACHINES

Item Size x Ply Type Make

7

8

5

6

3

4

1

2

9

10

11

12

13

16.9x24x12

16.9x24x12

IND

IND

15.5×25 XTLA

16.9x28x12

IND

16.9x28x12

16.9x28x10

16.9×28

16.9x28x14

IND

IND

XM27

IND

16.9x24x12

16.9x28x12

16.9x28x12

14.9x24x12

16.9×28

IND

TRAC

IND

IND

IND

2WS/2WD MACHINES

21

22

23

24

25

11.0x16x12 RIB

11.0x16x12 RIB

11Lx16x12 IND

10.5x18x10 IND

12.0x18x12 IND

2WS/4WD MACHINES

36

37

38

39

31 14×17.5×10 IND

32 14×17.5×10

IND

34 12.0x18x12

35 12.0x18x12

IND

IND

335 x18

335 x20

340 x18

XM27

12.5x18x10 IND

XM27

IND

ARMSTRONG

GOODYEAR

MICHELIN

ARMSTRONG

GOODYEAR

GOODYEAR

MICHELIN

NOKIA

GOODYEAR

OLYMPIC

OLYMPIC

GOODYEAR

GOODYEAR

Remarks

TUBELESS

bar

Pressure lbf/in

2

2.6

TUBELESS 2.6

38

38

TUBELESS

TUBELESS

2.5

2.6

36

38

TUBELESS

TUBELESS

TUBELESS

TUBE

2.6

2.2

2.7

2.6

38

32

39

38

TUBELESS

TUBELESS

TUBE

TUBELESS

TUBELESS

2.6

2.6

2.6

2.75

2.5

38

38

38

40

36

ARMSTRONG TUBELESS

GOODYEAR TUBELESS

ARMSTRONG

FIRESTONE

FIRESTONE

TUBELESS

TUBELESS

TUBELESS

ARMSTRONG

GOODYEAR

FIRESTONE

OLYMPIC

TUBELESS

TUBELESS

TUBELESS

TUBELESS

MICHELIN TUBELESS

GOODYEAR TUBELESS

MICHELIN

GOODYEAR

TUBE

TUBELESS

3.8

3.8

3.5

4.25

3.5

4.25

3.0

3.2

4.4

4.2

4.4

3.8

3.5

64

61

64

55

51

55

55

51

62

51

62

43.5

46

Items 4, 5, 6, 7,8, 9, 10, 11, 13, 38 must have steering lock restriction stops fitted.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

2 — 2

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

2 — 2

Tyre Pressures

Note:

If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

Rear Wheels

AWS MACHINES

Item Size x Ply Type Make

7

8

5

6

3

4

1

2

9

10

11

12

13

16.9x24x12

16.9x24x12

IND

IND

15.5×25 XTLA

16.9x28x12

IND

16.9x28x12

16.9x28x10

16.9×28

16.9x28x14

16.9x24x12

16.9x28x12

16.9x28x12

14.9x24x12

16.9×28

IND

IND

XM27

IND

IND

TRAC

IND

IND

IND

ARMSTRONG

GOODYEAR

MICHELIN

ARMSTRONG

GOODYEAR

GOODYEAR

MICHELIN

NOKIA

GOODYEAR

OLYMPIC

OLYMPIC

GOODYEAR

GOODYEAR

2WS MACHINES

21

22

23

24

25

26

27

28

29

30

31

32

16.9x24x10

16.9x24x12

19.5x24x10

19.5x24x12

21L x24x12

18.4x26x12

18.4x26x12

18.4x26x12

16.9x28x12

16.9x28x12

16.9x28x12

IND

IND

IND

IND

IND

TRAC

TRAC

IND

TRAC

TRAC

IND

16.9×28 XM27

33

34

18.4x30x14

ARMSTR0NG

GOOOYEAR

ARMSTRONG

ARMSTRONG

GOODYEAR

GOODYEAR

OLYMPIC

GOODYEAR

OLYMPIC

FIRESTONE

IND GOODYEAR

16.9×28 IND GOODYEAR

TUBELESS

TUBELESS

TUBELESS

TUBELESS

TUBELESS

TUBELESS

TUBELESS

TUBELESS

TUBELESS

TUBE

GOODYEAR TUBELESS

MICHELIN TUBELESS

TUBE

TUBELESS

Remarks bar

Pressure lbf/in

2

TUBELESS 2.6

TUBELESS 2.6

38

38

TUBELESS

TUBELESS

TUBELESS

TUBELESS

2.5

2.6

2.6

2.2

36

38

38

32

TUBELESS

TUBE

TUBELESS

TUBELESS

TUBE

TUBELESS

TUBELESS

2.7

2.6

2.6

2.6

2.6

2.75

2.5

38

40

36

39

38

38

38

2.2

2.2

1.9

2.3

2.2

2.5

2.4

2.0

2.2

2.2

2.2

2.5

2.0

2.5

32

32

32

36

29

36

32

36

35

29

32

32

28

33

Note:

12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table above.

Items 4, 5, 6, 7,8, 9, 10, 11, 13 must have steering lock restriction stops fitted.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

3 — 1

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

3 — 1

Front Axle

Note:

It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced.

ALL WHEEL STEER MACHINES

Type

Designation

Installation

Weight

(dry, with no steer rams and without wheels)

Overall Gear Ratio

Crownwheel and Pinion Ratio

Number of Teeth

Crownwheel

Pinion

Hub Reduction

Input Type

Oscillation

Toe — in

Castor Angle

Camber Angle

King — pin inclination

JCB spiral bevel input with epicyclic hub reduction

SD70

Centre pivot

385 kg (850 lbs) approximately

24.975:1

4.625:1

37

8

5.4:1

Yoke

± 5°

0°

0°

1°

0°

2 WHEEL STEER MACHINES (4 Wheel Drive)

Type

Designation

Installation

Weight

(dry, with no steer rams and without wheels)

Hub Reduction

Input Type

Oscillation

Toe — in

Castor Angle

Camber Angle

King — pin inclination

Ratios

Overall

Crownwheel and Pinion

Number of Teeth

Crownwheel

Pinion

JCB spiral bevel input with epicyclic hub reduction

SD55

Centre pivot

330 kg (728 lbs) approximately

5.4:1

Yoke

± 5°

0 °

0 °

1 °

0 °

OPTION 1

16.2:1

3:1

OPTION 2

19.2:1

3.556:1

33

11

32

9

2 WHEEL STEER MACHINES (2 Wheel Drive)

Type

Installation

Weight

(dry, with steer ram and without wheels)

Oscillation

Toe — in

Castor Angle

Camber Angle

JCB centre oscillation, non-driven

Centre pivot

239 kg (525 lbs) approximately

± 5°

0°

0°

3 ° positive

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

3 — 2

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

3 — 2

Rear Axle

Note:

It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced.

ALL WHEEL STEER MACHINES

Type

Designation

Installation

Number of steer rams

Weight (dry, with no steer rams and without wheels)

Half (Axle) Shaft Braking/Type

Input Type

Oscillation

Toe — in

Castor Angle

Camber Angle

King — pin inclination

Hub Reduction

Ratios

Overall

Crownwheel and Pinion

Number of Teeth

Crownwheel

Pinion

2 WHEEL STEER MACHINES

Type

Designation

Installation

Weight (dry and without wheels)

Half (Axle) Shaft Braking/Type

Input Type

Hub Reduction

Ratios

Overall

Crownwheel and Pinion

Number of Teeth

Crownwheel

Pinion

3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking. Pinion mounted park brake disc.

SD80

Rigid pad mount

1 (Double rod)

410 kg (904 lbs) approx.

5 friction plate, 6 counter plate (each half shaft)

Yoke

± 5°

0 °

0 °

1 °

0 °

5.4:1

OPTION 1

15.78:1

2.923:1

38

13

OPTION 2

18.16:1

3.363:1

37

11

OPTION 3

13.7:1

2.538:1

33

13

3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking. Pinion mounted park brake disc.

PD70

Rigid pad mount

386 kg (851 lbs) approx.

5 friction plate, 6 counter plate (each half shaft)

Yoke

5.4:1

OPTION 1

15.78:1

2.923:1

38

13

OPTION 2

18.16:1

3.363:1

37

11

OPTION 3

13.7:1

2.538:1

33

13

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

4 — 1

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

4 — 1

Synchro Shuttle Gearbox

Description

Designation

Weight (dry)

2WD

4WD

Gear Ratios

1st

2nd

3rd

4th

Torque Converter

Torque Converter Dia.

Torque Converter Identification

Torque Multiplication at Stall

Combined torque converter, reverser, and gearbox unit.

Synchromesh manual gear selection. Electro hydraulic selection of forward and reverse.

SS700 (4 wheel drive)

* 170 kg (375 lb)

* 200 kg (441 lb)

Std Ratio

5.56:1

Low Ratio

6.56:1

3.45:1

1.83:1

1.00:1

4.06:1

1.90:1

1.00:1

310 mm (12.2 in.)

04/600580 04/600581

2.52:1 3.01:1

Converter Pressures (in neutral)

Converter In at 50 deg.C

Converter In at 100 deg.C

Converter Out at 50 deg.C

Converter Out at 100 deg.C

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

Lubrication Pressures (in neutral)

At 50 deg.C

At 100 deg.C

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

bar

1.5 — 2.5

5.3 — 6.7

0.5 — 1.3

4.1 — 4.9

0.8 — 1.6

3.0 — 4.0

0.3 — 0.9

2.1 — 2.9

bar

0.3 — 0.9

1.8 — 2.4

0.1 — 0.3

1.3 — 2.1

kgf/cm

2

1.5 — 2.5

5.4 — 6.8

0.5 — 1.3

4.2 — 5.0

0.8 — 1.6

3.1 — 4.1

0.3 — 0.6

2.1 — 3.0

kgf/cm

2

0.3 — 0.9

1.8 — 2.4

0.1 — 0.3

1.3 — 2.1

lbf/in

2

22 — 36

77 — 97

7 — 19

59 — 71

12 — 23

43 — 58

4 — 9

30 — 42

lbf/in

2

4 — 13

26 — 35

1 — 4

19 — 30

Main Line Pressure (in neutral) †

At 50 deg. C

At 100 deg.C

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

Clutch Pressures †

Flow Rates (in neutral)

Cooler at 50 deg.C

Cooler at 100 deg.C

Pump at 50 deg.C

bar

11.0 — 13.0

13.0 — 15.6

10.2 — 12.2

11.4 — 14.0

kgf/cm 2

11.2 — 13.3

13.3 — 16.0

10.4 — 12.4

11.8 — 14.3

lbf/in 2

159 — 188

188 — 226

148 — 177

165 — 203

All clutch pressures should be the same as

Mainline Pressure

to within 0.7 bar (10 lbf/in 2 )

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

L/min

7.7 — 11.0

13.9 — 20.0

5.2 — 8.2

14.5 — 17.5

11.5 — 15.5

24.0 — 33.0

US gal/min

2.0 — 2.9

3.6 — 5.3

1.1 — 2.2

3.8 — 4.6

3.0 — 4.1

6.7 — 8.8

UK gal/min

1.7 — 2.4

3.0 — 4.4

1.1 — 1.8

3.2 — 3.8

2.5 — 3.4

5.3 — 7.3

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section F

5 — 1

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

5 — 1

Powershift Gearbox — 6 Speed

Description

Designation

Weight (dry)

2WD

4WD

Gear Ratios

1st

2nd

3rd

4th

5th

6th

Torque Converter

Torque Converter Dia.

Torque Converter Identification

Torque Multiplication at Stall

Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft, 6 speed and 4 wheel drive clutch packs giving 6 forward and 4 reverse speeds. Electronically controlled gear selection.

PS766 (4 wheel drive)

T.B.A.

T.B.A.

Forward

8.17:1

4.90:1

3.62:1

2.25:1

1.35:1

1.00:1

Reverse

6.45:1

4.76:1

1.78:1

1.31:1

—

—

310 mm (12.2 in.)

04/600580 04/600581

2.52:1 3.01:1

Converter Pressures (in neutral)

Converter In at 50 ºC 1000 rev/min

Converter Out at 50 ºC

2000 rev/min

1000 rev/min

2000 rev/min

Converter Inlet Relief Valve Pressure (max.)

bar

2.0 — 4.95

4.0 — 6.8

0.6 — 2.25

1.25 — 2.50

7.1

kgf/cm

2

2.0 — 5.0

4.1 — 6.9

0.6 — 2.3

1.3 — 2.6

7.2

lbf/in

2

29 — 72

58 — 99

8.7 — 33

18 — 36

103

*

Lubrication Pressures (in neutral)

At 50 ºC 1000 rev/min

2000 rev/min

Main Line Pressure (in neutral)

At 50 ºC 1000 rev/min

2000 rev/min

Flow Rates (in neutral)

Cooler at 50 ºC

Pump at 50 ºC

Control Solenoid Valves

Coil Resistance

0.25 — 1.0

0.50 — 1.0

11.4 — 15.7

12.4 — 17.0

0.26 — 1.0

0.51 — 1.0

11.6 — 16.0

12.6 — 17.3

3.6 — 14.5

7.3 — 14.5

165 — 228

180 — 246

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

L/min

14.0 MIN

17.0 MIN

16.0 MIN

34.0 MIN

US gal/min

3.7 MIN

4.5 MIN

4.2 MIN

9.0 MIN

3 way, 2 position, normally closed, integral suppression diode.

7.5 Ohm @ 20 ºC

UK gal/min

3.1 MIN

3.7 MIN

3.5 MIN

7.5 MIN

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

6 — 1

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

6 — 1

Powershift Gearbox — 4 Speed

Description

Designation

Weight (dry)

2WD

4WD

Gear Ratios

1st

2nd

3rd

4th

Torque Converter

Torque Converter Dia.

Torque Converter Identification

Torque Multiplication at Stall

Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs giving 4 forward and 4 reverse speeds.

PS764 (4 wheel drive)

T.B.A.

T.B.A.

7.97:1

4.29:1

1.86:1

1.00:1

310 mm (12.2 in.)

04/600580 04/600581

2.52:1 3.01:1

Converter Pressures (in neutral)

Converter In at 50 ºC

Converter Out at 50 ºC

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

Converter Inlet Relief Valve Pressure (max.)

Lubrication Pressures (in neutral)

At 50 ºC 1000 rev/min

2000 rev/min

bar

2.0 — 4.95

4.0 — 6.8

0.6 — 2.25

1.25 — 2.50

7.1

0.25 — 1.0

0.50 — 1.0

kgf/cm

2

2.0 — 5.0

4.1 — 6.9

0.6 — 2.3

1.3 — 2.6

7.2

0.26 — 1.0

0.51 — 1.0

lbf/in

2

29 — 72

58 — 99

8.7 — 33

18 — 36

103

3.6 — 14.5

7.3 — 14.5

*

Main Line Pressure (in neutral)

At 50 ºC

Flow Rates (in neutral)

Cooler at 50 ºC

Pump at 50 ºC

Control Solenoid Valves

Coil Resistance

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

1000 rev/min

2000 rev/min

11.4 — 15.7

12.4 — 17.0

L/min

14.0 MIN

17.0 MIN

16.0 MIN

34.0 MIN

11.6 — 16.0

12.6 — 17.3

US gal/min

3.7 MIN

4.5 MIN

4.2 MIN

9.0 MIN

3 way, 2 position, normally closed, integral suppression diode.

7.5 Ohm @ 20 ºC

165 — 228

180 — 246

UK gal/min

3.1 MIN

3.7 MIN

3.5 MIN

7.5 MIN

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

7 — 1

www.WorkshopManuals.co.uk

Transmission

Technical Data

Section F

7 — 1

Engine Stall Speed Combinations

The stall speed figures on the following pages are intended as a guide to assist with machine fault diagnosis. The figures relate to tests conducted at an ambient of 25 deg. C and barometric pressure of 100 kPa (sea level). Note that changes in ambient temperature, pressure and humidity and fuel grade will affect engine power and hence the stall figures.

As an example, at 10,000 ft the power reduction of a naturally aspirated engine could be 29% and for a turbo engine 8%.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

www.WorkshopManuals.co.uk

Engine Stall Speed Combinations — Two wheel steer (2WS) machines, Low emission 1000 series engine

Note.

On all double pump options the test is to be carried out with single pump option selected.

3CX 3CX 3CXT 3CXT 3CXT

Std. Lft Std. Lft

Hi. Lft

3CXT

3CX 3CX

Hi Lft Contra Contra

Engine Speed @ Stall Combination

1.Convertor only.

Max.r.p.m.

Min.r.p.m.

2160

2060

2150

2040

2.Convertor + M.R.V.

Max.r.p.m.

Min.r.p.m.

1700 1690

1550 1530

Build specification.

Engine size.

N.A. (75hp) (56kw) n

T2 (92hp) (69kw)

T3 (100hp) (75kw) n

2150 2140

2045 2035

1805 1800

1665 1655 n n

2140

2035

1745

1590 n

2130

2025

1735

1585 n

2190

2100

1835

1700 n

2190

2090

1825

1690 n

Convertor type.

W300 (3.01)

W300 (2.52) n n n n n n n n

Pump size.

29 + 23cc

33/23cc

36/26cc

41/26cc

41/29cc

74cc variable

Fan Ratio.

1 to 0.85

1 to 1.06

1 to 1.16

n n n n n n n n n n n n n n n n

Air Conditioning

None

Europe

R.O.W.

n n n n n n n n n n n

Purchased from www.WorkshopManuals.co.uk

Convertor type.

W300 (3.01)

W300 (2.52)

Pump size.

29 + 23cc

33/23cc

36/26cc

41/26cc

41/29cc

74cc variable

Fan Ratio.

1 to 0.85

1 to 1.06

1 to 1.16

Air Conditioning

None

Europe

R.O.W.

www.WorkshopManuals.co.uk

Engine Stall Speed Combinations — All wheel steer (AWS) machines, Low emission 1000 series engine

Note.

On all double pump options the test is to be carried out with single pump option selected.

4CX

4CX

3CX 3CX 3CX 3CX

Super Super

Super Super

Std. Lft Std. Lft Hi. Lft Hi. Lft

Engine Speed @ Stall Combination

1.Convertor only.

Max.r.p.m.

Min.r.p.m.

2150

2045

2140

2035

2140

2035

2130

2025

2.Convertor + M.R.V.

Max.r.p.m.

Min.r.p.m.

1805 1800

1665 1655

Build specification.

Engine size.

N.A. (75hp) (56kw)

T2 (92hp) (69kw)

T3 (100hp) (75kw) n n

1745

1590 n

1735

1585 n

2190

2100

1835

1700 n

2190

2090

1825

1690 n

4CX 4CX

Super Super

4C 4C

2200

2095

1825

1685 n

2190

2090

1820

1685 n

4CX

Super

4CX

2235

2140

N/A

N/A n

4CX

Super

4CX

2230

2130

N/A

N/A n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Purchased from www.WorkshopManuals.co.uk

Convertor type.

W300 (3.01)

W300 (2.52)

Pump size.

29 + 23cc

33/23cc

36/26cc

41/26cc

41/29cc

74cc variable

Fan Ratio.

1 to 0.85

1 to 1.06

1 to 1.16

Air Conditioning

None

Air Con.

www.WorkshopManuals.co.uk

Engine Stall Speed Combinations — Two wheel steer (2WS) machines, Low emission 1000 series engine, (North America)

Note.

On all double pump options the test is to be carried out with single pump option selected.

214E 214e 214 214 215E

214T

215E

214T

214T 215

217

Engine Speed @ Stall Combination

1.Convertor only.

Max.r.p.m.

Min.r.p.m.

2130

2020

2130

2020

2.Convertor + M.R.V.

Max.r.p.m.

Min.r.p.m.

1330

970

Build specification.

Engine size.

N.A. (75hp) (56kw) n

T2 (92hp) (69kw)

T3 (100hp) (75kw)

1330

970 n

2160 2140

2060 2025

1700 1685

1550 1520 n n

2270

2170

1870

1720 n

2270

2160

1865

1715 n

2190

2090

1825

1690 n

2190

2090

1820

1685 n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Purchased from www.WorkshopManuals.co.uk

Convertor type.

W300 (3.01)

W300 (2.52)

Pump size.

29 + 23cc

33/23cc

36/26cc

41/26cc

41/29cc

74cc variable

Fan Ratio.

1 to 0.85

1 to 1.06

1 to 1.16

Air Conditioning

None

Air Con.

www.WorkshopManuals.co.uk

Engine Stall Speed Combinations — All wheel steer (AWS) machines, Low emission 1000 series engine, (North America)

Note.

On all double pump options the test is to be carried out with single pump option selected.

214S 215S

217S

Engine Speed @ Stall Combination

1.Convertor only.

Max.r.p.m.

Min.r.p.m.

2190

2090

2190

2090

2.Convertor + M.R.V.

Max.r.p.m.

Min.r.p.m.

1825 1820

1690 1685

Build specification.

Engine size.

N.A. (75hp) (56kw)

T2 (92hp) (69kw)

T3 (100hp) (75kw) n n n n n n n n n n n n

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Front Axle — Steer Drive Type SD55, SD70

Component Identification

The illustration shows a typical steer drive front axle.

A

Yoke connection to propshaft

B

Pinion

C

Crownwheel

D

Differential unit

E

Drive shaft

F

Universal coupling

G

Reduction gear hub

H

Steer swivel trunnion bearings

J

Axle pivot

K

Oil fill and drain plugs

A

E

F

G

B

J

D

C

K

H

Purchased from www.WorkshopManuals.co.uk

A355950

www.WorkshopManuals.co.uk

Rear Axle — Steer Drive Type SD80

Component Identification

The illustration shows a typical steer drive rear axle. 2WS machines are fitted with non steer axles (PD70). These axles are similar to the axle shown but do not feature steer swivels or drive shaft universal joints.

A

Park brake disc. The disc is fitted to the pinion instead of a yoke. The propshaft is bolted to the centre of the disc. The axle casing also carries a bracket for location of the park brake caliper.

B

Pinion

C

Crownwheel

D

Differential unit

Note:

Items A, B, C, and D form the ‘drive head’ part of the axle.

E

Drive shaft

F

Universal coupling

G

Reduction gear hub

H

Steer swivel trunnion bearings

L

In-board oil immersed multi-plate disc brakes

M

Brake actuating piston

N

Hydraulic brake lines

C

D

N

M

L

E

H F

G

A396760

A

B

Purchased from www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

T

S

B www.WorkshopManuals.co.uk

R

E

A

D

K

W

V

C

Q

L

M

N

P

H

J

F

A388431

G

U

Purchased from www.WorkshopManuals.co.uk

Y

X

A396620

www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

Component Identification

A

Forward/reverse clutch unit

B

Transmission oil pump

C

Torque converter pressure regulating valve

D

Oil pressure maintenance valve

E

Solenoid control valve

F

Mainshaft

G

Synchromesh unit — 3rd/4th gears

H

Layshaft

J

Synchromesh unit — 1st/2nd gears

K

Transfer gear, output shaft and yoke

L

4WD output yoke (if fitted)

M

2/4WD clutch unit (if fitted)

N

4WD solenoid control valve (if fitted)

P

Oil strainer

Q

Oil filter

R

Gear selection turret assembly

S

Torque Converter

T

Driveshaft (drives machine main hydraulic pump)

U

Hydraulic pump mounting face

V

Torque converter relief valve

W

Oil pressure switch

X

Hose connection — to cooler

Y

Hose connection — from cooler

Z

Gearbox oil cooler

Principle of Operation

This Illustration shows a typical JCB Syncro Shuttle which consists of a torque converter, hydraulic reverser unit, and integral manual 4-speed gearbox.

The reverser unit

A

has a pair of hydraulically operated clutches giving forward — neutral — reverse drive. Oil pressure is provided by a crescent type pump

B

driven at engine speed by the drive lugs of the torque converter. The oil pressure is controlled by maintenance valve

D

, and clutch selection is achieved by means of an electric solenoid valve

E

.

Drive is transferred from the reverser unit by helical gears to the mainshaft

F

, which carries the 3rd/4th synchromesh unit

G

, and to the layshaft

H

, which carries the 1st/2nd synchromesh unit

J

.

Synchromesh unit

G

is of the ‘Blocking Pin’ type, a full description of which is given in this section.

Synchromesh unit

J

features rings and cones with a sliding sleeve.

Drive is transmitted finally via the output shaft

K

to the rear axle. If 4 wheel drive is selected, the front wheels are also driven via 4 wheel drive output yoke

L

.

Driveshaft

T

is permanantly driven by the engine and runs through the hollow forward/reverse unit shaft to the back of the gearbox. The shaft (

T

) drives the gearbox mounted machine main hydraulic pump.

Gearbox oil is cooled by an air blast cooler

Z

. The cooler is part of the front mounted machine ‘cooling pack’.

Z

A401330

Purchased from www.WorkshopManuals.co.uk

N

E

D

F

E1

E2

K www.WorkshopManuals.co.uk

V

B

C

Q

A2

A A1

M

S

A3

A4

L

P

Purchased from www.WorkshopManuals.co.uk

Key to Oil Flow & Pressure

Full Pressure

Pressure

Lubrication

Exhaust

A396520

Z

www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

Hydraulic and Electrical Operation

Oil from the pump

B

is fed through an internal passage via the filter to the pressure maintenance valve

D

, which maintains pressure to the solenoid valve

E

for clutch selection. Excess oil from the maintainance valve flows back through the casing to the torque converter

S

. Oil enters the converter between the converter hub and the stator support, and leaves between the stator and the input shaft.

Pressure in t he c o nvert er is c o nt ro lled b y a regulat ing valve

C

w hic h d ump s oil from t he converter line back to the sump.

Torque converter relief valve

V

acts as a safety valve should the system pressure suddenly rise obove normal, protecting the torque converter from being damaged.

Oil from the torque converter

S

flows out of the transmission to the external oil cooler

Z

, returning at the rear of the transmission unit to pass through t he c ent re o f t he reverser shaf t f o r c lut c h lubrication.

Lubrication oil is also provided via a pump drain line to the forward/reverse front shaft bearing

A4

.

The drain from pressure maintenance valve

D

also provides lubrication for idler gear bearing

F

.

Solenoid Valve

(

E

)

Operation

Pressurised oil at the solenoid valve

E

is used to control the forward/reverse clutches

A1

and

A2

.

Forward:

In the diagram, electrical solenoid

E1

is energised by the forward/reverse control lever in the cab.

Pressurised oil is diverted to the forward clutch

A1

and forward is selected. A restrictor orifice in the feed to the solenoid valve modulates the pressure to the clutch to smooth engagement. At the same time oil from reverse clutch

A2

is diverted back to the sump via solenoid valve

E

.

Reverse:

When the reverse is selected electrical solenoid

E2

is energised and pressurised oil is diverted to the reverse clutch

A2

. At the same time oil from clutch

A1

is diverted back to the sump

Neutral:

When neutral is selected (via the control lever or the t ransm issio n d um p b ut t o n), t he f lo w o f t he pressurised oil is blocked at the solenoid valve. No solenoids are energised and no clutches engaged.

Fo r a f urt her d et ailed d esc rip t io n ref er t o

Forward/Reverse Clutch — Operation

.

The 2/4WD unit

M

is controlled by solenoid valve

N

.

For a full description of 2/ 4 wheel drive clutch operationrefer to

2/4WD Clutch Operation

.

Key

A

Forward/reverse clutch unit

A1

Forward clutch

A2

Reverse clutch

A3

Forward/reverse front shaft

A4

Forward/reverse front shaft bearing

B

Transmission oil pump

C

Torque converter pressure regulating valve

D

Oil pressure maintenance valve

E

Solenoid control valve

F

Idler gear bearing

K

Output shaft bearing

L

4WD output yoke (if fitted)

M

2/4WD clutch unit (if fitted)

N

4WD solenoid control valve (if fitted)

P

Oil strainer

Q

Oil filter

S

Torque Converter

V

Torque converter relief valve

Z

Oil Cooler

Purchased from www.WorkshopManuals.co.uk

R

D

C

B www.WorkshopManuals.co.uk

A

2

J 3

5

N

G

A401080

E

F

L

Q

H

A401070

C

K

M

1

Purchased from www.WorkshopManuals.co.uk

P

www.WorkshopManuals.co.uk

Powershift Gearbox

Component Identification

A

Torque converter

B

Forward/input clutch assembly

C

Reverse clutch assembly

D

Mainshaft assembly

E

Layshaft assembly

F

2/4 wheel drive clutch assembly

G

Torque converter relief valve

H

Oil pressure maintenance valve

J

Transmission oil pump

K

6 speed assembly (if fitted)

L

4WD output yoke

M

Hose connection — to oil cooler

N

Hose connection — from oil cooler

P

Oil strainer

Q

Oil filter

R

Driveshaft (drives machine main hydraulic pump)

1

Speed sensor

2

Gear drive to reverse unit clutch assembly

3

Transmission oil pressure switch

4

Steering column mounted gear selection switch

5

Solenoid control valves

6

Gearbox oil cooler

Principle of Operation

The J CB Po w ershif t is an elec t ro — hyd raulic t ransmission unit . Gear shift ing and d irec t ion selection are controlled using multi-disc clutch packs.

Elec t ric ally op erat ed solenoid valves

5

d ivert p ressurised o il (p ro vid ed b y p um p

J

) t o t he selected clutch packs.

A combined lever/swivel switch

4

on the steering column actuates both gear ratio and direction solenoids.

The Powershift unit consists of a torque converter

A

, forw ard c lut c h assemb ly

B

, reverse c lut c h assem b ly

C

, layshaft assem b ly

E

, m ainshaft assembly

D

, 2/4 wheel drive clutch assembly

F

.

6 speed gearboxes incorporate a ‘6 speed’ shaft and clutch assembly

K

.

The forward clutch assembly

B

is driven by the torque converter

A

. The reverse clutch assembly

C

is permanently driven via constant meshing of spur gears

2

. On 6 sp eed gearb oxes t he 6 sp eed assembly is also driven via meshing gears

2

.

Driveshaft

R

is permanently driven by the engine and runs through the hollow forward/reverse unit shaft to the back of the gearbox. The shaft (

R

) d rives t he g earb o x m o unt ed m ac hine m ain hydraulic pump.

Strainer

P

and filter

Q

are used to prevent potential system contamination by filtering dirt particles.

Gearbox oil is cooled by an air blast cooler

6

. The cooler is part of the front mounted machine ‘cooling pack’.

6

4

Purchased from www.WorkshopManuals.co.uk

A401330

Section F

17 — 3

5

1

2 3

Xs

3

2 1

Us

Ts

Ss

Ws

Vs

Ys

Zs

Transmission

Basic Operation

www.WorkshopManuals.co.uk

H

G

K

N

E

D

C

1

B R

L

Q

F

P

J

M

A

Section F

17 — 3

6

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

17 — 4

Transmission

Basic Operation

www.WorkshopManuals.co.uk

Powershift Gearbox

Hydraulic and Electrical Operation

Oil pump

J

is directly driven by the engine via the torque converter.

Oil from the pump

J

is fed through an internal passage via the filter

Q

to the pressure maintenance valve

H

, which maintains pressure to the solenoid valve block for clutch selection. Excess oil from the maintainance valve flows b ac k t hrough t he c asing t o t he t orq ue c onvert er

A

.

Pressure in the converter is controlled by a relief valve

G

which dumps oil from the converter line back to the sump.

Oil from the torque converter

A

flows out of the gearbox at position

M

to the external oil cooler

6

, returning to the solenoid valve manifold block

5

at position

N

. The oil then flows through internal oilways providing lubrication for clutches and bearings before returning to the gearbox sump.

The torque converter

A

is a fluid coupling bolted to a drive plate which in turn is bolted to the engine flywheel. As the engine starts to rotate, the converter gives smooth power take off gradually increasing the torque transmitted. This torque is transferred from the converter assembly to the clutch/ gear assemblies via input shaft on the forward clutch assembly

B

.

Forward clutch assembly

B

contains two hydraulically operated clutches; one clutch (

T

) provides a forward low ratio drive and the other (

U

) a forward high ratio drive. Each clutch is controlled by a 2-position solenoid valve. When the applicable solenoid is energised, pressurised oil is directed to either the forward low (solenoid

Ts

) or forward high (solenoid

Us

) clutch.

The reverse clutch assembly

C

is similar to the forward clutch assembly. It contains two hydraulically operated clutches; one clutch (

W

) provides a reverse low ratio drive and the other (

V

) a reverse high ratio drive. 2-position solenoid valves when energised, direct pressurised oil to either the reverse low (solenoid

Ws

), or reverse high

(solenoid

Vs

) clutch.

Both the mainshaft and the layshaft assemblies have a single clutch each. Solenoid valve

Zs

, when energised, directs pressurised oil to the layshaft clutch

Z

. Solenoid valve

Ys

, when energised, directs pressurised oil to the mainshaft clutch

Y

.

On 6 speed gearboxes, the 6 speed clutch

X

is controlled via solenoid valve

Xs

.

Note:

The 6 speed clutch assembly is so called as it is fitted to 6 speed, and not 4 speed gearboxes. However, the clutch is NOT engaged when 6th gear is selected. See the adjacent table.

Note:

All the clutches work on the same principle. For a full description of operation see

Systems Description

.

The 2/4 wheel drive unit

F

also has a single clutch

S

. When

4WD is selected, pressurised oil is directed via solenoid valve

Ss

to the 4WD clutch. When 2WD is selected a connection from the clutch to the transmission sump is made. For a full description of 2/4 wheel drive clutch op erat ion see

Systems Description, 2/ 4WD Clutch

Operation

When a gear is selected via the control switch in the cab, 2 clutches are always engaged. By selecting different pairs of clutches different gear ratios are engaged. On 4 speed gearboxes the solenoids are electrically controlled using relays. On 6 speed gearboxes the solenoids are controlled by an electronic control unit (ECU) mounted in the cab.

Speed sensor

1

is used to enable the gear selection to be managed automatically as required.

Example — 2nd gear forward 4WD (6 speed gearbox)

In the schematic, the gearbox is shown with 2nd gear forward engaged. 2nd gear forward requires the forward low clutch

T

and layshaft clutch

Z

to be engaged. When the gear selection switch is moved to 2nd gear forward, the electrical control system energises solenoid valves

Ts

and

Zs

. Pressurised oil is diverted to the back of pistons in both clutches to engage the drive. At the same time all other solenoids are de-energised, diverting oil from the back of the other clutch pistons to the gearbox sump. 4WD clutch

S

is also energised to give 4 wheel drive.

The t ab les show w hic h c lut c hes and solenoid s are engaged for each gear selection.

Note:

Solenoid valve

Xs

controls clutch

X

, solenoid valve

Zs

controls clutch

Z

and so on.

4 Speed Powershift

Gear Clutches engaged

1st

Forward Reverse

T,Z W,Z

2nd

3rd

4th

U,Z

T,Y

U,Y

V,Z

W,Y

V,Y

4th

5th

6th

6 Speed Powershift

Gear Clutches engaged

1st

Forward Reverse

X,Z W,Z

2nd

3rd

T,Z

U,Z

V,Z

W,Y

X,Y

T,Y

U,Y

—

—

V,Y

Ts

Us

Ws

Vs

Ss

Ys

Zs

Xs

5

9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

17 — 4

Key

A

Torque converter

B

Forward clutch assembly

C

Reverse clutch assembly

D

Mainshaft assembly

E

Layshaft assembly

F

2/4 wheel drive clutch assembly

G

Torque converter relief valve

H

Oil pressure maintenance valve

J

Transmission oil pump

K

6 speed assembly (if fitted)

L

4WD output yoke

M

Hose connection — to oil cooler

N

Hose connection — from oil cooler

P

Oil strainer

Q

Oil filter

R

Driveshaft (drives machine main hydraulic pump)

S

2/4WD clutch

Ss

2/4WD clutch solenoid

T

Forward low ratio clutch

Ts

Forward low ratio clutch solenoid

U

Forward high ratio clutch

Us

Forward high ratio clutch solenoid

V

Reverse high ratio clutch

Vs

Reverse high ratio clutch solenoid

W

Reverse low ratio clutch

Ws

Reverse low ratio clutch solenoid

X

6 speed clutch (6 speed gearbox only)

Xs

6 speed clutch solenoid (6 speed gearbox only)

Y

Mainshaft clutch

Ys

Mainshaft clutch solenoid

Z

Layshaft clutch

Zs

Layshaft clutch solenoid

1

Speed sensor

5

Solenoid valve manifold block

6

Gearbox oil cooler

Issue 1

Section F

17- 5

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

17 — 5

Powershift Gearbox — 6 Speed

ShiftMaster Operation Characteristics

Central to the system is the ShiftMaster ECU (Electronic

Control Unit)

A

. The unit receives ‘inputs’ from electrical devices such as the gear select switch

B

. Depending on the input signals the ECU ‘outputs’ energise electrical devices such as gearbox solenoid control valves

C

. For a full description of how the ShiftMaster electrical system works see

Electrical Connections — Powershift Gearbox — 6

Speed

Start up

When the starter switch is set to the ON position the ECU performs a series of self checks. If the checks are valid

three beeps

sound. After the checks the ECU selects neutral even if forward or reverse is selected on the column lever. To select forward or reverse the operator must cycle the lever through neutral.

If the checks fail,

1 or 2 beeps

will sound and the ECU will enter an appropriate limp mode (see

Limp modes

)..

‘Manual’ gear select

The operator can ‘manually’ select 1st, 2nd and 3rd gears using the column switch. When down shifting (say from 3rd to 2nd) the ECU checks to see if the machine road speed is suitable before down shifting the gearbox. If the road speed is too high a

repeating double beep

is sounded. When the road speed reduces to a pre-set value the ECU down shifts the gearbox and the beeps will stop.

Kick down operation

A floor mounted kickdown switch enables the operator to down shift to the next lowest gear. The ECU checks to see if the machine road speed is suitable before down shifting the gearbox. If the road speed is too high a

single double beep

is sounded.

Pressing the kick down switch a second time causes the

ECU to select the previous gear.

‘Automatic’ gear selection

When A (auto) and F (forward) are selected on the column switch, the ECU selects 4th, 5th or 6th gears, mainly according to road speed. The gearbox will automatically up shift and down shift. 2WD†† will also be selected.

To enable up shifts the accelerator pedal must be pressed, this prevents up shifting when coasting down hill for example, thus ensuring maximum machine control.

Note that the ECU does not automatically shift gears in response to engine load.

When A (auto) and R (reverse) are selected the ECU selects

4th gear and 2WD††. There is no automatic gear shifting in reverse.

†† On machines with 4WB (4 wheel brake), if the operator has selected 4WB the ECU will automatically select 4WD (4 wheel drive) when the brake pedal is pressed.

Park brake ON

When the park brake is on, the ECU will hold the gearbox in neutral even if forward or reverse are selected. A

continuous tone

is sounded.

1

2

3

A

Transmission dump

When the operator presses the dump switch the ECU selects neutral by de-energising one clutch only. This enables smooth re-engagement of gears when the dump button is released.

Limp modes

When necessary the ECU will provide alternative gear selection should faults occur. This enables the machine to be moved (‘limped’) under its own power. For full details of the limp modes see

Fault Finding — Powershift Gearbox

.

A

A405710

C

B

F

N

R

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

18 — 1

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 1

Powershift Gearbox

Drivepaths — 4 Speed

1F

1st GEAR FORWARD (4 wheel drive)

Clutches Engaged

T

Z

S

Forward Low

Layshaft

2/4 Wheel Drive

Solenoids Energised

Ts

Zs

Ss

2F

2nd GEAR FORWARD (4 wheel drive)

Clutches Engaged

U

Forward High

Z

Layshaft

S

2/4 Wheel Drive

Solenoids Energised

Us

Zs

Ss

3F

3rd GEAR FORWARD (4 wheel drive)

Clutches Engaged Solenoids Energised

T

Forward Low

Ts

Y

S

Mainshaft

2/4 Wheel Drive

Ys

Ss

4F

4th GEAR FORWARD (4 wheel drive)

Clutches Engaged Solenoids Energised

U

Y

S

Forward High

Mainshaft

2/4 Wheel Drive

Us

Ys

Ss

Ss

Ys

Zs

Ts

Us

Ws

Vs

A396740

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

18 — 2

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 2

Powershift Gearbox

2F

1F

Y

W V

T U

Z

S

Y

W V

T U

Z

S

A396670

A396660

4F

3F

Y

W V

T U

Z

S

A396680

Y

W V

T U

Z

S

A396690

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

18 — 3

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 3

Powershift Gearbox

1R 2R

Y

W V

T U

Z

S

A396700

Y

W V

T U

Z

S

A396710

4R

3R

Y

W V

T U

Z

S

A396720

Y

W V

T U

Z

S

A396730

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

18 — 4

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 4

Powershift Gearbox

Drivepaths — 4 Speed

1R

1st GEAR REVERSE (4 wheel drive)

Clutches Engaged

W

Reverse Low

Z

S

Layshaft

2/4 Wheel Drive

Solenoids Energised

Ws

Zs

Ss

2R

2nd GEAR REVERSE (4 wheel drive)

Clutches Engaged

V

Reverse High

Z

S

Layshaft

2/4 Wheel Drive

Solenoids Energised

Vs

Zs

Ss

3R

3rd GEAR REVERSE (4 wheel drive)

Clutches Engaged Solenoids Energised

W

Y

S

Reverse Low

Mainshaft

2/4 Wheel Drive

Ws

Ys

Ss

4R

4th GEAR REVERSE (4 wheel drive)

Clutches Engaged

V

Reverse High

Y

S

Mainshaft

2/4 Wheel Drive

Solenoids Energised

Vs

Ys

Ss

Ss

Ys

Zs

Ts

Us

Ws

Vs

A396740

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

18 — 5

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 5

Powershift Gearbox

Drivepaths — 6 Speed

1F

1st GEAR FORWARD (4 wheel drive)

Clutches Engaged

X

‘6 Speed’

Z

S

Layshaft

2/4 Wheel Drive

Solenoids Energised

Xs

Zs

Ss

2F

2nd GEAR FORWARD (4 wheel drive)

Clutches Engaged

T

Forward Low

Z

S

Layshaft

2/4 Wheel Drive

Solenoids Energised

Ts

Zs

Ss

3F

3rd GEAR FORWARD (4 wheel drive)

Clutches Engaged Solenoids Energised

U

Z

Forward High

Layshaft

Us

Zs

S

2/4 Wheel Drive

Ss

4F

4th GEAR FORWARD (4 wheel drive)

Clutches Engaged Solenoids Energised

X

‘6 Speed’

Xs

Y

S

Mainshaft

2/4 Wheel Drive

Ys

Ss

5F

5th GEAR FORWARD (4 wheel drive)

Clutches Engaged

T

Forward Low

Y

S

Mainshaft

2/4 Wheel Drive

Solenoids Energised

Ts

Ys

Ss

6F

6th GEAR FORWARD (4 wheel drive)

Clutches Engaged

U

Y

S

Forward High

Mainshaft

2/4 Wheel Drive

Solenoids Energised

Us

Ys

Ss

Ts

Us

Ws

Vs

Ss

Ys

Zs

Xs

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

18 — 6

1F www.WorkshopManuals.co.uk

Transmission

Basic Operation

2F

Section F

18 — 6

Y

X

W V

T U

Z

S

Y

X

W V

T U

Z

S

4F

3F

A387850

A387860

9803/3280

5F

Y

X

W V

T U

Z

S

Y

X

W V

T U

Z

S

A387870

A387880

6F

X

W V

T U

Y Y

Z

S

A387890

Purchased from www.WorkshopManuals.co.uk

Z

X

W V

T U

S

A387900

Issue 1

Section F

18 — 7

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 7

1R 2R

Y

X

W V

T

U

Z

S

A387910

Y

X

W V

T U

Z

S

A387920

3R

4R

9803/3280

X

W V

T U

Y

Y

Z

S

A387930

Purchased from www.WorkshopManuals.co.uk

Z

X

W V

T U

S

A387940

Issue 1

Section F

18 — 8

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

18 — 8

Powershift Gearbox

Drivepaths — 6 Speed

1R

1st GEAR REVERSE (4 wheel drive)

Clutches Engaged Solenoids Energised

W

Z

Reverse Low

Layshaft

Ws

Zs

S

2/4 Wheel Drive

Ss

2R

2nd GEAR REVERSE (4 wheel drive)

Clutches Engaged Solenoids Energised

V

Reverse High

Vs

Z

S

Layshaft

2/4 Wheel Drive

Zs

Ss

3R

3rd GEAR REVERSE (4 wheel drive)

Clutches Engaged

W

Reverse Low

Y

S

Mainshaft

2/4 Wheel Drive

Solenoids Energised

Ws

Ys

Ss

4R

4th GEAR REVERSE (4 wheel drive)

Clutches Engaged Solenoids Energised

V

Y

Reverse High

Mainshaft

Vs

Ys

S

2/4 Wheel Drive

Ss

Ts

Us

Ws

Vs

Ss

Ys

Zs

Xs

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

20 — 1

www.WorkshopManuals.co.uk

Transmission

Basic Operation

Section F

20 — 1

Torque Converter

Component Identification

A Impeller

B Turbine

C Reaction member

D Drive plate

E Engine flywheel

F Drive to gearbox input shaft

G Spline location for reaction member

H Direct drive from the engine to the gearbox oil pump

J Direction of oil flow

Principle of Operation

The torque converter is similar to a fluid coupling, which utilises the centrifugal force exerted in the transmission oil to transmit power from the engine to the gearbox. It multiplies the torque from the engine and functions as a combined clutch and infinitely variable reduction gearbox

The torque converter is enclosed in a casing and consists of three basic parts, the impeller

A

, reaction member

C

, and turbine

B

.

Impeller

A

is driven by the engine.

Reaction member

C

does not rotate. Its hub engages with a splined tube on the gearbox oil pump and is held stationary.

Turbine

B

is engaged with the splined end of the gearbox input shaft.

The impeller

A

, driven by the engine, forms one set of shaped blades, it can be likened to a centrifugal pump imparting energy to the transmission oil. This energy is transferred to another set of shaped blades, which form the turbine

B

The turbine is connected to the gearbox and converts the energy back to a mechanical torque.

When the impeller

A

is rotating faster than the turbine

B

, the fixed reaction member

C

causes some of the energy in the oil to be transferred back to the impeller

A

. This has the effect of multiplying the torque available.

When the impeller

A

(input) is running much faster than the turbine

B

(output) there is a substantial circulation of transmission oil around the blades. The oil circulation is maximum when the turbine (output) is stalled, and is almost zero when the impeller and turbine speeds are equal i.e. the ratio is near 1:1. If the turbine (output) is stalled whilst the impeller (input) is revolving, all the power is dissipated as heat.

Because of the absence of a direct mechanical connection between the engine and the gearbox therefore, the flexibility of the torque converter drive greatly reduces wear on the transmission, absorbing shocks and torsional vibration from the engine. The engine cannot be stalled due to overload, as the fluid coupling slips.

H

A

J

C

G

B

F

D

E

A401340

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

25 — 1

www.WorkshopManuals.co.uk

Transmission

Systems Description

Section F

25 — 1

C

A B

D

F

E

G

9803/3280

H

Purchased from www.WorkshopManuals.co.uk

J

Issue 1

Section F

25 — 2

www.WorkshopManuals.co.uk

Transmission

Systems Description

Section F

25 — 2

Syncro Shuttle Gearbox

Synchromesh (Blocking Pin Type)

The gearbox is fitted with ‘ Blocking Pin’ synchromesh, comprising the following parts.

SYNCRO HUB (A)

controls the operation of the synchromesh unit and gear selection, the selector fork fitting into the outer groove. Internal dog teeth link the selected gear to the drive shaft. Through the syncro hub centre are two sets of holes for the blocker pins (

C

) and the split energiser pins (D), spaced alternately.

SYNCRO RINGS (B)

are rigidly joined by the blocker pins, with the split energiser pins held, in counterbores, between the two syncro rings.

BLOCKER PINS (C)

have a narrow neck in the centre, against which the syncro hub transmits radial drive during gear changes. The edges of the blocker pin neck and their mating syncro hub holes are designed so that, as the radial loads are reduced, the syncro hub can slide over the shoulder of the blocker pin.

SPLIT ENERGISER PINS (D)

take the initial axial load of the syncro hub on the shoulder of the split energiser pin neck.

As the axial load reaches approximately 400 N (40.8 kg; 90 lb) the internal springs allow the split energiser pin to collapse and the syncro hub to move axially.

SYNCRO CUPS (E)

take the frictional drive from the syncro ring on their inner faces. The syncro cups are splined to drive their respective gears whilst synchronisation is taking place.

SYNCHROMESH — OPERATION

Diagram

F

shows the gearbox with first gear engaged.

Syncro ring

B

is in contact with syncro cup

E

and the syncro hub dog teeth are linking first gear to the shaft gear. In this position the split energiser pins

D

are ‘collapsed’.

When selecting second gear the syncro hub

A

slides along the split energiser pins until the pin recess and the syncro hub flange are in line. At this point the split energiser pins open and the syncro rings are moved by the syncro hub pushing on the split energiser pin shoulder.

Initial contact between the syncro ring and the syncro cup starts to synchronise the speed of the shaft and second gear. The rotational force of the syncro ring is taken by the blocker pin against the edge of the syncro hub hole, as at

G

.

As the axial load on the syncro hub increases, the split energiser pin ‘ collapses’ and the conical faces of the blocking pin and syncro hub hole come into contact, as at

H

.

Further increases in the axial loads increase the frictional grip of the syncro ring and the syncro cup, causing the shaft and gear speeds to synchronise.

As the speeds are synchronised the radial load on the blocker pin and the syncro hub is reduced. This allows the syncro hub to slide freely along the blocker pin and engage its dog teeth with second gear, see diagram

J

.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Syncro Shuttle Gearbox

Forward/Reverse Clutch Operation www.WorkshopManuals.co.uk

The forward/reverse clutch unit

1

transfers drive from the input shaft

A3

to either gear

G1

or gear

G2

depending on which of the two clutches (

A1

or

A2

) is engaged, giving forward or reverse drive. When neither clutch is engaged, neutral is selected.

The clutches are of the wet, multi-plate type.

The c lut c h housings and inp ut shaft are a one p iec e assembly

A3

. The assembly is permanently driven by the engine via the torque converter. Clutch counter plates

3

are also permanenty driven via meshing teeth inside the clutch housings.

Clutch friction plates

4

are meshed with the gear/plate carriers (

G1

and

G2

).

In the diagram, clutch

A1

is engaged. The counter plates

3

and friction plates

4

are pressed together by hydraulically actuated piston

5

. Drive is then transmitted from the input shaft to the gear

G1

.

Clutch

A2

is disengaged and no drive is transmitted to gear/plate carrier

G2

. The gear is also free to rotate on the input shaft assembly.

Actuation of the hydraulic pistons

10

and

5

is controlled via three position solenoid valve

E

†.

When neut ral is selec t ed , so leno id s

E1

and

E2

are deactivated and the flow of pressurised oil to the clutches is blocked. Springs

8

and

9

move the pistons away from the clutch plates and oil from both pistons is vented to the sump.

When either forward or reverse is selected, the solenoid valve

E

diverts pressurised oil via cross drillings inside the input shaft

A3

to the appropriate clutch (piston

10

or

5

) in the unit. Pressure from the other clutch is vented to the sump via the solenoid valve spool. Oil is prevented from leaking by seals

6

on the pistons and ring seals

7

on the input shaft

A3

.

† The valve

E

is shown using symbols. For an explanation of how the symbols work, see

Section E

,

Introduction to

Hydraulic Schematic Symbols

.

Purchased from www.WorkshopManuals.co.uk

Syncro Shuttle Gearbox

Forward/Reverse Clutch Operation

www.WorkshopManuals.co.uk

1

A3 G1

A1 6 5 6

10

A2

G2

E1

4

3

8 9

Purchased from www.WorkshopManuals.co.uk

7

E

E2

A390970

www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

2/4 Wheel Drive Clutch Operation

— Pressure ON/Spring OFF Type

4 Wheel Drive Operation

This clutch is of the ‘Pressure-ON (4WD)/Spring-

OFF (2WD)’ type. The clutch is engaged and disengaged by introducing or dumping pressurised oil behind piston

C

via a solenoid valve

A

. The solenoid valve is operated by a switch in the cab.

When the switch is in the 4 wheel drive position, solenoid valve

A

is energised. The energised solenoid

A1

causes the valve spool to move and form a connection between ports

3

and

2

.

Pressurised oil is directed to piston

C

via ports

3

and

2

. The piston moves, against spring

D

, to press the friction/counter plates of clutch pack

B

together, thus driving the output yoke

E

.

Purchased from www.WorkshopManuals.co.uk

A406200

www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

2/4 Wheel Drive Clutch Operation

— Pressure ON/Spring OFF Type (cont’d)

2 Wheel Drive Operation

When the switch is in the 2 wheel drive position, solenoid valve

A

is de-energised. With the solenoid

A1

de-energised, the valve spool moves under the force of the spring

A2

. The oil supply to the piston

C

is blocked (shown at port

3

). At the same time oil vents from the back of piston

C

to the sump via ports

1

and

2

.

Because there is no pressure behind piston

C

, the friction/counter plates of clutch pack

B

now freely rotate on the output shaft, thus disengaging drive to the front axle.

Purchased from www.WorkshopManuals.co.uk

A406210

www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

2/4 Wheel Drive Clutch Operation

— Spring ON/Pressure OFF Type

4 Wheel Drive Operation

This clutch is of the ‘Spring-ON (4WD)/Pressure-

OFF (2WD)’ type. The clutch is engaged and disengaged by introducing or dumping pressurised oil behind piston

C

via a solenoid valve

A

. The solenoid valve is operated by a switch in the cab.

When the switch is in the 4 wheel drive position, solenoid valve

A

is de-energised. With the solenoid

A1

de-energised, the valve spool moves under the force of the spring

A2

. The oil supply to the piston

C

is blocked, (shown at port

3

). At the same time oil vents from the back of piston

C

to the sump via ports

1

and

2

.

Because there is no pressure behind piston

C

, the clutch friction/counter plates of clutch pack

B

are forced together by disc springs

D

, thus driving the output yoke

E

.

Purchased from www.WorkshopManuals.co.uk

A406220

www.WorkshopManuals.co.uk

Synchro Shuttle Gearbox

2/4 Wheel Drive Clutch Operation

— Spring ON/Pressure OFF Type (cont’d)

2 Wheel Drive Operation

When the switch is in the 2 wheel drive position, solenoid valve

A

is energised. The energised solenoid

A1

causes the valve spool to move and form a connection between ports

3

and

2

.

Pressurised oil is directed to piston

C

via ports

3

and

2

. The piston moves actuating sleeve

F

and then pressure plate

G

against the force of springs

D

, thus releasing the spring force on the clutch friction/counter plates of clutch pack

B

.

Because there is no spring force, the friction/counter plates of clutch pack

B

now freely rotate on the output shaft, thus disengaging drive to the front axle.

Purchased from www.WorkshopManuals.co.uk

A406230

Powershift Gearbox

Clutch Operation — Forward, Reverse www.WorkshopManuals.co.uk

† The valve

E

is shown using symbols. For an explanation of how the symbols work, see

Section E

,

Introduction to

Hydraulic Schematic Symbols

.

The forward and reverse clutch units are very similar in d esig n and o p erat e in t he sam e w ay. The f o llo w ing description refers to one unit and can be applied to either the forward or reverse clutch units.

The clutch

1

transfers drive from the input shaft

A3

to either gear

G1

or gear

G2

depending on which of the two clutches

(

A1

or

A2

) is engaged, transferring drive to the mainshaft.

When neither clutch is engaged, neutral is selected.

The clutches are of the wet, multi-plate type.

The c lut c h housings and inp ut shaft are a one p iec e assembly

A3

. The assembly is permanently driven by the engine via the torque converter. Clutch counter plates

3

are also permanenty driven via meshing teeth inside the clutch housings.

Clutch friction plates

4

are meshed with the gear/plate carriers (

G1

and

G2

).

In the diagram, clutch

A1

is engaged. The counter plates

3

and friction plates

4

are pressed together by hydraulically actuated piston

5

. Drive is then transmitted from the input shaft to the gear

G1

.

Clutch

A2

is disengaged and no drive is transmitted to gear/plate carrier

G2

. The gear is also free to rotate on the input shaft assembly.

Actuation of the hydraulic pistons

10

and

5

is controlled via two position solenoid valves

E1

and

E2

†.

When neut ral is selec t ed , so leno id s

E1

and

E2

are deactivated and the flow of pressurised oil to the clutches is blocked. Springs

8

and

9

move the pistons away from the clutch plates and oil from both pistons is vented to the sump.

When for example clutch

A1

is selected to be engaged, solenoid valve

E1

is energised and solenoid valve

E2

is deenergised. Pressurised oil is diverted via cross drillings inside the input shaft

A3

to the clutch piston

5

. Pressure from clutch

A2

is vented to the sump via the solenoid valve spool

E2

. Oil is prevented from leaking by seals

6

on the pistons and ring seals

7

on the input shaft

A3

.

Clutch Operation — Mainshaft, Layshaft, 6 Speed

The mainshaft, layshaft and 6 speed units all incorporate one clutch and not two, as in the forward and reverse units.

The operation of the single clutches is the same as for one clutch in the forward or reverse units.

Clutch Operation — 2/4 Wheel Drive Clutch

The 2/4 wheel drive clutch is similar to the Synchro Shuttle

2/4 wheel drive clutch. See

Synchro Shuttle Gearbox, 2/4

Wheel Drive Clutch Operation

.

Purchased from www.WorkshopManuals.co.uk

Powershift Gearbox

Clutch Operation — Forward, Reverse

www.WorkshopManuals.co.uk

1

A3 G1

A1 6 5 6

10

A2

G2

7

8 9

4

3

Purchased from www.WorkshopManuals.co.uk

A396830

E1

E2

Section F

32 — 1

www.WorkshopManuals.co.uk

Transmission

Electrical Connections

Section F

32 — 1

Powershift Gearbox — 4 Speed

Introduction

This section explains how the electrical system works when the following gearbox functions are operated:

1st, 2nd, 3rd and 4th gears forward

Neutral

1st, 2nd, 3rd and 4th gears reverse

Transmission dump

Park brake switch

The 4-speed powershift gearbox is controlled using conventional relays. The relays at

A

are operated via the column mounted gear and forward/reverse lever

B

. The transmission dump switch

C

or park brake switch

D

also operate a relay at

A

. The contacts inside the relays energise the gearbox mounted solenoid control valves

E

.

Diode ‘gates’

F

are also used as logic switches.

To access the relays and connectors it is necessary to remove the front/steering console panel

X

and side panels

Y

, refer to

Section B

for the correct procedure.

1

2

3

4

B

F

N

R

X

F

A

D

C

Y

Y

9803/3280

E

A404800

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

32 — 2

www.WorkshopManuals.co.uk

Transmission

Electrical Connections

Section F

32 — 2

Powershift Gearbox — 4 Speed (cont’d)

Electrical Connections — Quick Reference

The tables show switch positions together with energised relay and gearbox solenoids for each gearbox function

(reverse gears are shown on the next page). The numbers show which contacts are ‘live’ and also relate to the actual connector pin numbers.

When fault finding it should be remembered that the system relies on the dump switch and park brake switches functioning correctly, failure of these switches will prevent forward or reverse gears being selected. From the tables it is possible to see common relay functions which can help trace faults. For example we can see that relay FF2 is energised to engage 1st or 2nd gear. Failure of these gears to select may indicate a fault with relay FF2.

Note that a non functioning relay or solenoid may not indicate a faulty component, the associated wires and connectors may have failed. For wire and connector details see the relevant schematic.

Diagram X

The diagram

X

(opposite) shows the electrical circuit for the gearbox control. It is shown with 3rd gear forward selected.

‘Live feed’ wires are coloured red and feed to earth are green.

Key

C50

DW

FL

FK

FG

FD2

FE2

FF1

FD1

FE1

FF2

NG

Reverse alarm

Park brake switch

Column switch connector

Diode gate connector

Transmission dump relay

Forward relay

Reverse relay

Interlock relay

Forward Hi/Lo relay

Reverse Hi/Lo relay

Mainshaft/Layshaft relay

Dump switch

Gearbox Solenoids

T

U

Y

Z

Forward low

Forward high

Mainshaft

Layshaft

Note:

Solenoid

S

is the

2/4WD solenoid. The 2/4WD select electrical system is not described in this section.

S

A405330

7

11

5

6

3

1

2

4

FK

3 2 1

7 6 5 4

11 10 9 8

14 13 12

FD2

FD1

FE2

FE1

FF2 FG

FF1

9803/3280

1

2

3

4

FL

1 2 3

4 5

6

7

8 9 10 11

12 13 14

12 1

9

2

3

13

4

4

10

F

N

R

14

7

F

N

R

NG

A

A B

B

A B

Purchased from www.WorkshopManuals.co.uk

3 2

3 2 1

DW

3 2 1

A404820

Issue 1

Section F

32 — 3

Powershift Gearbox — 4 Speed

Transmission

Electrical Connections

www.WorkshopManuals.co.uk

Section F

32 — 3

Gearbox function

Column Switch

FL

Relay

FG

Relay

FD2

Relay

FE2

Relay

FF1

Diode Gate

FK

Relay

FD1

Relay

FE1

Relay

FF2

Dump Forward Reverse Interlock Forward

Hi Lo

Reverse

Hi Lo

Mainshaft

Layshaft

1st GEAR

FORWARD

1F

14 — 12

7 — 4

1

1 — 4

3 — 5, 1 — 2

4

5

1

3

2

1

1 — 4

4

6

9 — 6

9

4

4

1

6

6 — 9

9

3 — 5, 1 — 2

5

1

3

2

Gearbox Solenoid

T

T,Z

Z

U

2nd GEAR

FORWARD

2F

14 — 9

7 — 4

1

1 — 4

3 — 5, 1 — 2

4

5

1

3

2

1

1 — 4

4

6

9 — 6

9

2

1

2 — 5, 1 — 4 8 -10, 6 — 7

5

4

10

6

8

7

3 — 5, 1 — 2

5

1

3

2

U,Z

Z

T

3rd GEAR

FORWARD

3F

7 — 4

1

1 — 4

3 — 5, 1 — 2

4

5

1

3

2

1

1 — 4

4

6

9 — 6

9

6 — 9

6

9

1 — 4

1

4

T,Y

Y

U

4th GEAR

FORWARD

4F

14 — 13

7 — 4

1

1 — 4

4

5

1

3 — 5, 1 — 2

3

2

1

1 — 4

4

6

9 — 6

9

3

2

3 — 6

6

5

8 -10, 6 — 7

10

6

8

7

1 — 4

1

4

Y

U,Y

NEUTRAL

N

1 — 4 1 — 4

1

4

1

4

TRANSMISSION DUMP

/PARK BRAKE ON

5

1

5 — 3, 1 — 2

3

2

A404630

9803/3280

Purchased from www.WorkshopManuals.co.uk

V T

X

U

Y

Z

DW

11

7

NG

FF2

4 2 5

1 3

FF1

6

10

9 7 8

C50

883

W

FE1

9

7 10

FD1

9

7 10

6 8 6 8

FD2

2

5

1

3

FE2

5 2 4

3 1

TO NEUTRAL

START RELAY

5 4

852

FG

3 1

FL

4 6 10

7

4 1

5

2

6

3

12 9 13

FL

14

A404640

Issue 1

Section F

32 — 4

Powershift Gearbox -4 Speed

Transmission

Electrical Connections

www.WorkshopManuals.co.uk

Gearbox function

Column Switch

FL

Relay

FG

Relay

FD2

Relay

FE2

Relay

FF1

Diode Gate

FK

Relay

FD1

Relay

FE1

Relay

FF2

Dump Forward Reverse Interlock Forward Reverse Mainshaft

Hi Lo Hi Lo Layshaft

1st GEAR

REVERSE

1R

14 — 12

7 — 10

1

1 — 4

4

1

1 — 4

4

5

1

3 — 5, 1 — 2 8 — 10, 7 — 6

4

3

2

10

6

8

7

4

1

6

6 — 9 3 — 5, 1 — 2

9

5

1

3

2

Gearbox Solenoid

W

Z

W,Z

V

2nd GEAR

REVERSE

2R

14 — 9

7 — 10

1

1 — 4

4

1

1 — 4

4

3 — 5, 1 — 2

8 — 10, 7 — 6

5

1

3

2

10

6

8

7

2

1

2 — 5, 1 — 4

5

4

8 — 10, 6 — 7 3 — 5, 1 — 2

10

6

8

7

5

1

3

2

Z

W

V,Z

3rd GEAR

REVERSE

3R

7 — 10

1

1 — 4

4

1

1 — 4

4

5

1

3 — 5, 1 — 2

8 — 10, 7 — 6

3

2

10

6

8

7

6 — 9 1 — 4

6

9

1

4

Y

W,Y

V

4th GEAR

REVERSE

4R

14 — 13

7 — 10

1

1 — 4

4

1

1 — 4

4

3 — 5, 1 — 2 8 — 10, 7 — 6

5

1

3

2

10

6

8

7

3

2

3 — 6

6

5

8 — 10, 6 — 7 1 — 4

10

6

8

7

1

4

V,Y

Y

A404740

FD2

2

5

1

3

FE2

5 2 4

3 1

TO NEUTRAL

START RELAY

5 4

852

FG

3 1

FL

4 6 10

7

5

2

6

3

12 9 13

FL

14

Section F

32 — 4

DW

11

7

Y

Z

C50

5

FF2

4

2 5

1 3

FF1

6 10

9

7

8

883

Y

W V T U

FE1

9 7 10

FD1

9 7 10

6 8 6 8

4 1

A404790

Issue 1

9808/3280

Purchased from www.WorkshopManuals.co.uk

Section F

32 — 5

www.WorkshopManuals.co.uk

Transmission

Electrical Connections

Section F

32 — 5

Powershift Gearbox — 4 Speed (cont’d)

Electrical Connections — Quick Reference (cont’d)

The tables show switch positions together with energised relay and gearbox solenoids for each gearbox function. The numbers show which contacts are ‘live’ and also relate to the actual connector pin numbers.

When fault finding it should be remembered that the system relies on the dump switch and park brake switches functioning correctly, failure of these switches will prevent both forward and reverse being selected. From the tables it is possible to see common relay functions which can help trace faults. For example we can see that relay FF2 is energised to engage 1st or 2nd gear. Failure of these gears to select may indicate a fault with relay FF2.

Note that a non functioning relay or solenoid may not indicate a faulty component, the associated wires and connectors may have failed. For wire and connector details see the relevant schematic.

Diagram Y

The diagram

Y

opposite shows the electrical circuit for the gearbox control. It is shown with 3rd gear reverse selected.

‘Live feed’ wires are coloured red and feed to earth are green.

Key

C50

DW

FL

FK

FG

FD2

FE2

FF1

FD1

FE1

FF2

NG

Reverse alarm

Park brake switch

Column switch connector

Diode gate connector

Transmission dump relay

Forward relay

Reverse relay

Interlock relay

Forward Hi/Lo relay

Reverse Hi/Lo relay

Mainshaft/Layshaft relay

Dump switch

Gearbox Solenoids

V

W

Y

Z

Reverse high

Reverse low

Mainshaft

Layshaft

Note:

Solenoid

S

is the

2/4WD solenoid. The 2/4WD select electrical system is not described in this section.

S

A405330

7

6

3

11

5

1

2

4

FK

3 2 1

7 6 5 4

11 10 9 8

14 13 12

FD2

FD1

FE2

FE1

FF2 FG

FF1

9803/3280

1

2

3

4

FL

1 2 3

4 5

6

7

8 9 10 11

12 13 14

12 1

9 2

3

13

4

4

10

F

N

R

14

7

F

N

R

NG

A

A B

B

A B

Purchased from www.WorkshopManuals.co.uk

3 2

3 2 1

DW

3 2 1

A404820

Issue 1

www.WorkshopManuals.co.uk

Section F

32 — 6

Transmission

Electrical Connections

Powershift Gearbox — 4 Speed

(Machines up to 933756)

Electrical Connections — Wires and Connectors

Although the system is straight forward in design it is never the less fairly complex in practice. For this reason schematics are divided into 2 parts:

Relay Actuation

and

Gearbox Solenoid Actuation

.

On the electrical diagram opposite the electrical connectors

(example, FA to LA) are shown looking on the mating face of each connector when they are disconnected.

The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding.

Before fault finding make sure that you understand how the the electrical circuits work. Most potential faults can be traced using a multimeter to carry out continuity checks on wires, switches and soleniod coils. Gearbox solenoid coils can be checked for the correct resistance value as given in

Technical Data

. See

Service Procedures, Electrical

Testing Methods

for more details.

Relay Actuation

For gearbox solenoid actuation see subsequent pages.

Component Key

(Relay actuation)

:

The following key identifies the component connectors on the opposite diagrams. Note that the wires coloured red show the electrical ‘live feed’ to the column gear lever.

h1

Harness — 721/10940 Front console

h2

Harness — 721/10942 Link

h3

Harness — 721/10936 Side console

h4

Harness — 721/10935 Engine/mainframe

Note:

For harness drawings see

Section C

.

Connectors (h1)

FA

h1

î h2

FB1

Earth point

FD1

Forward high/low relay

FD2

Forward relay

FE1

Reverse high/low relay

FE2

Reverse relay

FF1

Interlock relay

FF2

Mainshaft/layshaft relay

FG

Transmission dump relay

FK

Diode gate

FL

Column gear lever

Connectors (h2)

LA

h2 î h1

LB

h2 î h3

Connectors (h3)

CA

h3

î h4

CB

h3 î h2

CCA

Fuses

CCB

Fuses

CM

Park brake relay

DW

Park brake switch

EA

Immobiliser

EAB

Link — immobiliser (if immobiliser is not fitted)

Connectors (h4)

NH

h4

î h3

NG

Transmission dump switch

MB1

Earth point

Splices (h1)

SL

SC

SG

SH

SK

SS

ST

Splices h2

SA

SB

Splices h3

SC

Splices h4

SA

Earth Points

Faults may be caused by poor earth connections. Although earth connections are shown opposite, it must be remembered that the cab assembly is earthed via further earth strap and cable connections. For details of these connections see

Section C, Machine Earth Connections

.

FK

FL

LA

FA FB1

9808/3280

Purchased from www.WorkshopManuals.co.uk

Section F

32 — 6

DW

NG LB

CB

NH

CA

DR2

MB1

A405320

Issue 2*

Section F

32 — 7

Powershift Gearbox — 4 Speed

Relay Actuation

(Machines up to 933756)

Transmission

Electrical Connections

www.WorkshopManuals.co.uk

Section F

32 — 7

9803/3280 h1

12 1

9

2

3

13

4

4

10

F

N

R

3

1

2

4

11

7

5

6

3 2 1

7 6

5

4

11 10 9 8

14 13 12

FK

3 2 1

7 6 5 4

11 10 9 8

14 13 12

11

7

5

6

3

1

2

4

815

934C

884

884A

858A

856A

856B

883E

9

4

10

12

13

14

7

1 2 3

4 5

6

7

8 9 10 11

12 13 14

FL

3 2 1

7 6

5

4

11 10 9 8

14 13 12

9

4

856

809

10

12

13

14

7

808

883

858

107A

107R

FD1, FE1

FD1, FE1

SL SU

SC

FD2

FE2

FF2

SH

SS

107

14

7

934

107

815

7

34

10

FA

12 24 30 36 48 60

1 13 25 31 39 49

FB1

621

FD1 FD2

600AC

809

5

10

3 6

884D

600AE

8

10

6

7

8

7

9

5

1

5 4 3

3

2

4

2

1

8 9 10

SA

FE1 FE2

600AD

808

1858A

5

10

3

6

2

600AF

884C

10

8

6

7

8

7

9

5

1

5 4 3

3

2

4

2

1

8 9 10

LA

60 48 36 30 24 12

7

34

10

934

107H

SA

934F

SB

107

815A

7

34

10

LB

12 24 30 36 48 60

49 39 31 25 13 1 1 13 25 31 39 49 h2

FF1 FF2

883B

600AG

3

10

5

6

1858C

600LF

8

10

6

7

8

7

9

5

1

5 4 3

3

2

4

2

1

8 9 10

ST

FG

107AL

934D

3

5

SK

5

1

6

7

8 9 10

5 4 3

2

1

3

2

4

CB

FD2

FD1

FE2

FE1

FF2 FG

FF1

60 48 36 30 24 12

49 39 31 25 13 1

107H

107

6

3

EA

4

3

2

1

5

6

7

8

EAB

5

6

7

8

4

3

2

1

6

3

7

34

10

934F

107H

815A h3

2c

h4

6

7

9

8 9 10

107

CM

5 4 3

3

DW

2

3 2 1

2

1

3

2 1

3 1 2

NH

815

107S

CCA

600BF

SC

10

13

11

9

7

4

3

1

19

17

15

14

12

10

8

6

4

2

20

18

16

9

619

002

FUSE A5

DR2

IGN

CA

A B

A B

A B

NG

MB1

600A

A B

600EZ

934A

SA

42

12 20 24 28 35 48

1 13 21 25 29 37

12 20 24 28 35 48

1 13 21 25 29 37

42

934F

A404520

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

32 — 8

Powershift Gearbox — 4 Speed

Gearbox Solenoid Actuation

(Machines up to 933756)

h1

Transmission

Electrical Connections

www.WorkshopManuals.co.uk

9808/3280

Section F

32 — 8

FD2

FD1

FE2

FE1

FF2 FG

FF1

852N

852P 1

846B

846

846

812

812/848

2

4

6

7

9

FD1 FD2

10

6

6

7

8

7

9

5

1

5 4 3

3

2

4

2

1

8 9 10

FE1 FE2

852P

1858

1858D

811

811/849

6

7

9

1

10

2

6

4

6

7

8

7

9

5

1

5 4 3

3

2

4

2

1

8 9 10

FB1

SA

621

600DN

600DP

50

49

851

850

811/849

811

812/848

812

19

16

15

13

11

6

FA

12 24 30 36 48 60

1 13 25 31 39 49

ST

600Z

851

850

849

811

848

812

LA

60 48 36 30 24 12

SC

49 39 31 25 13 1

50

49

600DN

600DP

19

16

15

13

11

6

851

850

811/849

811

812/848

812

C10

1 11 10 9 3 8 4

12 11 10 9

5 6

1 2 3 4

8 7

600Z

LC

1 2 3 4 5 6

12 11 10 9 8 7

1 11 10 9 3 8 4 h2 h5

999

850

851

999

1858B

846B

FF1 FF2

6

7

9

1

2

4

10

6

6

7

8

7

9

5

1

5 4 3

3

2

4

2

1

8 9 10

848

600BX

812

600BS

F

1

2

1 2

C30

2 1

T

E

1

2

1 2

C20

I

2 1

U

849

600CA

1

2

1 2

C60

J

2 1

W

811

600BT

1

2

1 2

C70

2 1

V

X

107

SS

SA

851

600BZ

850

600BY

FG

107AD 1

852N 4

5

1

6

7

8 9 10

5 4 3

2

1

3

2

4

G

1

2

1 2

C40

2 1

Y

H

1

2

1 2

C50

2 1

Z

A404530

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

32 — 9

9808/3270

LA

FA FB1 www.WorkshopManuals.co.uk

LC

C10

G H

F E I J

A404900

Transmission

Electrical Connections

Section F

32 — 9

Powershift Gearbox — 4 Speed (cont’d)

(Machines up to 933756)

Electrical Connections — Wires and Connectors

Gearbox Solenoid Actuation

For relay activation see previous page.

Component Key

(solenoid activation)

:

The following key identifies the component connectors on the diagrams opposite. Note that the wires coloured green show the electrical ‘feed to earth’ for the gearbox mounted solenoids. Live feed (wires coloured red) to the relay switches is supplied via the dump relay

FG

. Note that the destination for wire 107 from splice

SS

is shown on the relay actuation diagram (previous page).

h1

Harness — 721/10940 Front console

h2

Harness — 721/10942 Link

h5

Harness — 721/10939 Gearbox

Note:

For harness drawings see

Section C

.

Connectors (h1)

FA

h1 î h2

FB1

Earth point

FD1

Forward high/low relay

FD2

Forward relay

FE1

Reverse high/low relay

FE2

Reverse relay

FF1

Interlock relay

FF2

Mainshaft/layshaft relay

FG

Transmission dump relay

X

For wire 107 destination see

Relay Actuation

diagram

Connectors (h2)

LA

h1 î h2

LC

h2 î h5

Connectors (h5)

C10

h5 — h2

C20

Gearbox solenoid U (labelled

E

)

C30

Gearbox solenoid T (labelled

F

)

C40

Gearbox solenoid Y (labelled

G

)

C50

Gearbox solenoid Z (labelled

H

)

C60

Gearbox solenoid W (labelled

I

)

C70

Gearbox solenoid V (labelled

J

)

Splices (h1)

SS

ST

Splices (h2)

SC

Splices (h5)

SA

Earth Points

Faults may be caused by poor earth connections. Although earth connections are shown opposite, it must be remembered that the cab assembly is earthed via further earth strap and cable connections. For details of these connections see

Section C, Machine Earth Connections

.

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

33 — 1

www.WorkshopManuals.co.uk

Transmission

Electrical Connections

Section F

33 — 1

Powershift Gearbox — 6 Speed

Introduction

This section explains how the Powershift 6 speed

(ShiftMaster) electrical system works .

Central to the system is the ShiftMaster ECU (Electronic

Control Unit)

1

. The unit receives ‘inputs’ from electrical devices such as the gear select switch

B

. Depending on the input signals the ECU ‘outputs’ energise electrical devices such as gearbox solenoid control valves

2

.

E

F

G

H

J

B

C

D

K

L

Component Identification

ECU input devices

Gear select switch

Forward/Neutral/Reverse select switch

Transmission dump switch

Gearbox oil temperature switch

Park brake switch

Transmission dump relay

Speed sensor — gearbox mounted

Kick down switch

Throttle switch

Gearbox oil pressure switch

1

2

3

A

B C

F

N

R

The ECU can be connected to diagnostics software loaded on a laptop PC. The commincations link is facilitated via diagnostics socket

3

. See

Powershift Gearbox — 6 Speed,

ShiftMaster Diagnostics — User Guide

.

Note:

The ECU also controls 2/4WD selection by activating relay

S

. 2/4WD electrical system is not described in this section.

ECU output — activated devices

N

P

R

S-Z

In-cab warning light — high gearbox oil temperature

In-cab warning light — low gearbox oil pressure

In-cab master warning light and buzzer

Gearbox solenoid control valves

Note:

For identification of in-cab warning lights see the machine Operator Handbook.

G

K

E

1

J H

GC

GB

B

C

D

A

J

H

E

G

F

3

T U W V

F

D

L

2

S Y Z X

A405360

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section F

33 — 2

www.WorkshopManuals.co.uk

Transmission

Electrical Connections

Section F

33 — 2

Powershift Gearbox — 6 Speed

ECU Electrical Connections

Electrical connections at the ECU are shown in the diagram below. Connections are divided into two groups;

GB

Connections to components mounted on the gearbox

GC

Connections to components mounted elsewhere on the machine.

For the key to the main components see

Component

Identification

on the previous page. For more detailed explanations of the electrical connections for gearbox control see subsequent pages.

Note:

When fault finding DO NOT use a multimeter on the

ECU connector pins. Only test the associated wiring, uncouple connectors GB and GC and then use a multimeter at the pins inside these connectors as applicable. Use the

ShiftMaster Diagnostics system to identify possible faults with the ECU See

Powershift Gearbox — 6 Speed,

ShiftMaster Diagnostics — User Guide

.

GB1

Feed from GC10

GB2

12v Feed

GB4

12v Feed

GB6

Diagnostics connector

GB7

Forward switch

GB8

2nd gear switch

GB13

Warning lamp

Low trans oil pressure

GB14

Speedometer input

GB17

Auto gear switch

GB18

1st gear switch

GB19

Throttle switch

GB20

Foot brake switch

(4WD/4 wheel brake)

GB24

Diagnostics connector

GB25

Master warning lamp

GB26

ECU Earth

GB27

3rd gear switch

GB28

Neutral switch

GB30

Parkbrake ON switch

GB36

ECU Earth

GB37

Trans dump switch

GB38

Reverse switch

GB39

Kickdown switch

GB40

4WD switch

GC3

Speed sensor input

GC4

Output — ‘Z’ solenoid

GC6

Output — ‘U’ solenoid

GC10

Feed to GB1

GC11

Switch

Low trans oil pressure

GC12

Output — ‘X’ solenoid

GC13

ECU Earth

GC15

Output — ‘Y’ solenoid

GC18

Output — ‘S’ 4WD solenoid

GC20

Output — ‘V’ solenoid

GC21

Switch

Trans oil temperature

GC23

Output — ‘W’ solenoid

GC24

Output — ‘T’ solenoid

12V

C

1

2

F

N

R

3

A

FORWARD

NEUTRAL

REVERSE

GEAR 1

GEAR 2

GEAR 3

GEAR A

GB7

GB28

GB38

GB18

GB8

GB27

GB17

IN

IN

IN

IN

IN

IN

IN

R

P

K

B

D

J

THROTTLE

GB19

D-4WD

GB20

DUMP

GB37

I-4WD

GB40

IN

IN

IN

IN

KICKDOWN

GB39

DRIVER INDICATOR

GB25

IN

OUT

F

LOW OIL PRESSURE

GB13

SPEEDOMETER

GB14

OUT

OUT

PARK BRAKE

GB30

IN

12V (IGNITION)

1

ShiftMaster ECU

OUT

OUT

OUT

OUT

GC4

GC6

GC12

GC15

‘Z’ SOLENOID

‘U’ SOLENOID

‘X’ SOLENOID

‘Y’ SOLENOID

OUT

OUT

OUT

OUT

GC18

GC20

GC23

GC24

4WD SOLENOID ‘S’

‘V’ SOLENOID

‘W’ SOLENOID

‘T’ SOLENOID

GND RTN

GC13

BANK 1 GROUND RETURN

S-Z

FREQ2

GC10

GC3

TRANS SPEED

SPEED

SENSOR

H

12V

IN

IN

GC11

LOW TRANS

OIL PRESS

L

E

GC21

HI TRANS

OIL TEMP

N

12V

A408760

DIAGNOSTICS

CONNECTOR

3

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

33 — 3

www.WorkshopManuals.co.uk

Transmission

Electrical Connections

Section F

33 — 3

Powershift Gearbox — 6 Speed

Electrical Connections — Quick Reference

The tables show live connector pins and also relevant earth destinations for given gearbox functions/systems as follows:

E.C.U. feeds and earths

Transmission Dump

Park Brake ON (Transmission Dump)

1, 2, 3, 4(A), 5(A), 6(A) Forward

(see following pages)

Neutral

(see following pages)

1, 2, 3, 4 Reverse

(See following pages)

The information is intended as an aid when checking for faulty wires or connectors by means of continuity tests using a multimeter. DO NOT use a multimeter on the ECU connector pins (connectors A and B). Only test the associated wiring, uncouple connectors GB and GC and then use a multimeter at the pins inside these connectors as applicable. Use the ShiftMaster Diagnostics system to identify possible faults with the ECU See

Powershift

Gearbox — 6 Speed, ShiftMaster Diagnostics — User

Guide

.

Note that interconnecting harness connectors are not shown here. For full details see the relevant expanded harness schematic in this section.

Note:

Identify dump relay FG1 by locating wire 1873 at pin 2 of the corresponding relay base.

GB

GC

GG

LE

NG

Key

A

C50

CM

DW

DZ

FL

FG1

FG2

Diagram X

The diagram

X

(opposite) shows the electrical circuit for the gearbox control. It is shown with neutral selected and the park brake ON. ‘Live feed’ wires are coloured red and feed to earth are green.

Gearbox solenoids

Reverse alarm

Park brake warning light relay

Park brake switch

Park brake relay

Column switch

Transmission dump relay

Reverse alarm relay

Harness connector — ECU ‘A’

Harness connector — ECU ‘B’

Throttle switch

Kick down switch

Transmission dump switch

E.C.U. A

B

A

GC

FG1

5 4 3

6

7

8 9 10

2 1873

2

1

GB

GB

3 2

3

2 1

DW

3

2 1

MB1

NG

A

A B

B

A B

9803/3280

Purchased from www.WorkshopManuals.co.uk

A408740

Issue 1

Section F

33 — 4

Transmission

Electrical Connections

Powershift Gearbox — 6 Speed

Gearbox function

TRANSMISSION DUMP

Dump Switch

NG

A — B (MB1)

Relay

FG1

3 — 5, 1 — 2

5

1

3

2

www.WorkshopManuals.co.uk

E.C.U.

GB

37

X

FROM IGNITION

RELAY 1

FROM PARKBRAKE

WARNING LIGHT

TO NEUTRAL

START RELAY

Gearbox function

PARK BRAKE ON

(TRANSMISSION DUMP)

Park Brake Switch

DW

1, 3, 2

Relay

DZ

(DR2) 8 — 10, 6 — 7 (DR2)

10

6

8

7

E.C.U.

GB

30

E.C.U.

Power supply & Earths

EARTH

EARTH

EARTH

Column Switch FL

Power supply

Fuse

E.C.U.

GB

E.C.U.

GC

Earth Point

A5

A7

4

2

26

36

13

FB1

FB1

FB1

Fuse

Switch Connector

FL

A6

7, 14

A7 A6 A5

5A 5A

7.5A

10A 3A 10A

7.5A

7.5A

5A

10A

25A 20A 25A

5A

10A

10A

15A

7.5A

15A 5A

15A 3A 15A 3A 30A 20A 5A 10A 15A 7.5A

DZ

A408730

FB1

Section F

33 — 4

PARKBRAKE RELAY

936

1

3

DW

2

P/BRAKE SWITCH

815

CM

DZ

C50

9

FUSE A5

10

107

REV ALARM

FG2

847

808

C17

3

SPEED

SENSOR

1

2

11

FUSE A6

12

FOR / REV

SWITCH

7

FL

F

4

N

6

R 10

14

13

FUSE A7

16

GEAR

SELECTOR

FL

136

1

12

2

9

3

5

A

13

107

809

808

883

856

857

858

30

PARKBRAKE

7

28

38

FORWARD

NEUTRAL

REVERSE

18

1st GEAR

8

2nd GEAR

27

17

3rd GEAR

AUTOMATIC

FG1

LE

1

1

GG

2

2

934

1876

992

991

2

BANK 2 +VE

1

ECU + FEED

4

BANK 1 +VE

B

NG

A

1873

GB

37

DUMP RELAY

39

KICKDOWN

19

THROTTLE

SWITCH

26

36

ECU

REVERSE ALARM

REVERSE ALARM

RELAY

SPEED SENSOR

3

24

1860

6

1861

20

1862

23

1863

12

1864

15

1865

4

1866

13

10

GC

1876

A

1

1

1

1

1

1

1

2

H

2

G

2

6

2

F

2

E

2

J

2

I

‘T’ SOLENOID

‘U’ SOLENOID

‘V’ SOLENOID

‘W’ SOLENOID

‘X’ SOLENOID

‘Y’ SOLENOID

‘Z’ SOLENOID

-VE

-VE

-VE

A409280

Issue 1

9808/3280

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section F

33 — 5

Powershift Gearbox — 6 Speed

Transmission

Electrical Connections

Electrical Connections — Quick Reference

The tables show live connector pins and also relevant earth destinations for given gearbox functions/systems as follows:

ECU feeds and earths

(see previous pages)

Transmission Dump

(see previous pages)

Park Brake ON (Transmission Dump)

(see previous pages)

1, 2, 3, 4(A), 5(A), 6(A) Forward

Neutral

1, 2, 3, 4 Reverse

The information is intended as an aid when checking for faulty wires or connectors by means of continuity tests using a multimeter. DO NOT use a multimeter on the ECU connector pins (connectors A and B). Only test the associated wiring, uncouple connectors GB and GC and then use a multimeter at the pins inside these connectors as applicable. Use the ShiftMaster Diagnostics system to identify possible faults with the ECU See

Powershift

Gearbox — 6 Speed, ShiftMaster Diagnostics — User

Guide

.

Remember that any interconnecting harness connectors are not shown here. For full details see the relevant expanded harness schematic in this section.

GB

GC

GG

LE

NG

Key

A

C50

CM

DW

DZ

FL

FG1

FG2

Diagram X

The diagram

X

(opposite) shows the electrical circuit for the gearbox control. It is shown with 1st gear reverse selected.

‘Live feed’ wires are coloured red and feed to earth are green.

Gearbox solenoids

Reverse alarm

Park brake warning light relay

Park brake switch

Park brake relay

Column switch

Transmission dump relay

Reverse alarm relay

Harness connector — ECU ‘A’

Harness connector — ECU ‘B’

Throttle switch

Kick down switch

Transmission dump switch

X

FROM IGNITION

RELAY 1

9

FUSE A5

10

107

FROM PARKBRAKE

WARNING LIGHT

TO NEUTRAL

START RELAY

808

CM

E.C.U. B

E.C.U. A

1

2

B

A

GB

GC

1 2 2 1

F E I

G H 6

J

FL

1 2 3

4 5 6 7

8 9 10 11

12 13 14

1

2

3

A

12 1

9

5

13

A

2

3

4

6

10

F

N

R

FB1

7

F

N

R

14

815

REV ALARM

FG2

11

FUSE A6

12

FOR / REV

SWITCH

7

FL

F

4

N

6

R 10

14

13

FUSE A7

16

GEAR

SELECTOR

FL

136

1

12

2

9

3

5

A

13

107

809

808

883

856

857

858

30

PARKBRAKE

7

28

38

FORWARD

NEUTRAL

REVERSE

18

1st GEAR

8

2nd GEAR

27

17

3rd GEAR

AUTOMATIC

FG1

LE

1

1

GG

2

2

934

1856

992

991

2

BANK 2 +VE

1

ECU + FEED

4

BANK 1 +VE

B

NG

A

1873

GB

37

DUMP RELAY

39

KICKDOWN

19

THROTTLE

SWITCH

26

36

A408710

847

PARKBRAKE RELAY

DZ

C50

C17

3

SPEED

SENSOR

ECU

1

2

3

24

1860

6

1861

20

1862

23

1863

12

1864

15

1865

4

1866

13

936

10

GC

1876

Section F

33 — 5

1

3

DW

2

P/BRAKE SWITCH

REVERSE ALARM

REVERSE ALARM

RELAY

SPEED SENSOR

A

1

1

1

1

1

1

1

2

6

2

G

2

H

2

F

2

E

2

J

2

I

‘T’ SOLENOID

‘U’ SOLENOID

‘V’ SOLENOID

‘W’ SOLENOID

‘X’ SOLENOID

‘Y’ SOLENOID

‘Z’ SOLENOID

-VE

-VE

-VE

A409290

Issue 1

9808/3280

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section F

33 — 6

Transmission

Electrical Connections

Section F

33 — 6

Gearbox function

Column Switch

FL

E.C.U.

GB

E.C.U.

GC

(Inputs) (Outputs)

Solenoid Connector

Labelled

1st GEAR

FORWARD

1F

14 — 12

7 — 4

18

7

4 (Z)

12 (X)

1, 2

(FB1)

1, 2

(FB1)

H

6

Gearbox Solenoid

Z

X

T

X , Z

2nd GEAR

FORWARD

2F

14 — 9

7 — 4

8

7

4 (Z)

24 (T)

1, 2

(FB1)

1, 2 (FB1)

H

F

Z

U

T , Z

3rd GEAR

FORWARD

3F

14 — 5

7 — 4

27

7

4 (Z)

6 (U)

1, 2 (FB1)

1, 2

(FB1)

H

E

U , Z

Z

4th GEAR (A)

FORWARD

A

14 — 13

7 — 4

17

7

15 (Y)

12 (X)

1, 2 (FB1)

1, 2

(FB1)

G

6

Y

X

T

X , Y

5th GEAR (A)

FORWARD

A

14 — 13

7 — 4

17

7

15 (Y)

24 (T)

1, 2

(FB1)

1, 2

(FB1)

G

F

Y

U

T , Y

17

7

15 (Y)

6 (U)

1, 2

(FB1)

1, 2 (FB1)

G

E

6th GEAR (A)

FORWARD

A

14 — 13

7 — 4

A408700

Y

U , Y

9808/3280

Purchased from www.WorkshopManuals.co.uk

Gearbox function

NEUTRAL

Column Switch

FL

E.C.U.

GB

7 — 6 28

N

Gearbox function

Column Switch

FL

E.C.U.

GB

E.C.U.

GC

(Inputs) (Outputs)

Solenoid Connector

Labelled

1st GEAR

REVERSE

1R

14 — 12

7 — 10

18

38

4 (Z)

23 (W)

1, 2

(FB1)

1, 2

(FB1)

H

I

Gearbox Solenoid

W

Z

W , Z

V

2nd GEAR

REVERSE

2R

14 — 9

7 — 10

8

38

4 (Z)

20 (V)

1, 2

(FB1)

1, 2 (FB1)

H

J

Z

W

V , Z

3rd GEAR

REVERSE

3R

14 — 5

7 — 10

27

38

15 (Y)

23 (W)

1, 2 (FB1)

1, 2

(FB1)

G

I

Y

W , Y

V

4th GEAR

REVERSE

4R (A)

A408720

14 — 13

7 — 10

17

38

15 (Y)

20 (V)

1, 2 (FB1)

1, 2

(FB1)

G

J

Y

V , Y

Issue 1

www.WorkshopManuals.co.uk

Section F

33 — 7

Transmission

Electrical Connections

Powershift Gearbox — 6 Speed

Electrical Connections — Wires and Connectors

Schematics are divided into 2 parts:

Input Controls

and

Gearbox Solenoid Actuation

.

On the electrical diagram opposite the electrical connectors

(example, FA to LA) are shown looking on the mating face of each connector when they are disconnected.

The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding.

Before fault finding make sure that you understand how the the electrical circuits work. The most effective method of fault finding is by means of ShiftMaster Daignostics software and a laptop PC, see

Service Procedures, Powershift

Gearbox — 6 speed, ShiftMaster Diagnostis — User Guide.

Having identified a faulty system, use the schematics to identify the relevant wires and connectors, continuity checks can then be carried out using a multimeter. Gearbox solenoid coils can be checked for the correct resistance value as given in

Technical Data

. See

Service Procedures,

Electrical Testing Methods

for more details.

Input Controls

For gearbox solenoid actuation see subsequent pages.

Component Key

(Input controls)

:

The following key identifies the component connectors on the opposite diagrams. Note that the wires coloured red show the electrical ‘live feed’ to the column gear lever and gearbox E.C.U..

h1

Harness — 721/10937 Front console

h2

Harness — 721/10971 Link

h3

Harness — 721/10970 Side console

h4

Harness — 721/10935 Engine/mainframe

h5

Harness — 721/10941 Transmission

Note:

For harness drawings see

Section C

.

Connectors (h1)

FA

h1

î h2

FB1

Earth point

FG

Transmission dump relay

Note:

Identify dump relay FG by locating wire 1873 at pin 2 of the corresponding relay base.

FL

Column gear lever

GB

E.C.U. connector A

GC

E.C.U. connector B

GG

Throttle switch

Connectors (h2)

LA

h2

î h1

LB

h2

î h3

LC

h2

î h5

LE

Kick down switch

Connectors (h3)

CA

h3

î h4

CB

h3 î h2

CM

Park brake warning light relay

CCA

Fuses

DR2

Earth point

DZ

Park brake relay

DW

Park brake switch

EA

Immobiliser

EAB

Link — immobiliser (if immobiliser is not fitted)

Connectors (h4)

NH

h4

î h3

NG

Transmission dump switch

MB1

Earth point

Splices (h1)

SA

SC

SF

SJ

SL

SS

Splices h2

SB

SC

Splices h3

DW

TF

Splices h4

SA

Splices h5

SA

Earth Points

Faults may be caused by poor earth connections. Although earth connections are shown opposite, it must be remembered that the cab assembly is earthed via further earth strap and cable connections. For details of these connections see

Section C, Machine Earth Connections

.

FL

C10

LC

GB GC

C17

LA

FA FB1

LE

9808/3280

Purchased from www.WorkshopManuals.co.uk

MB1

FG

Section F

33 — 7

DW

GG

NG LB

CB

NH

CA

DR2

A408640

Issue 1

www.WorkshopManuals.co.uk

Section F

33 — 8

Powershift Gearbox — 6 Speed

Input Controls

9803/3280

Transmission

Electrical Connections

Section F

33 — 8

10

12

6

13

5

14

7

9

4

1 2 3

4 5 6 7

8 9 10 11

12 13 14

FL

3 2 1

7 6 5 4

11 10 9 8

14 13 12

10

12

6

13

5

9

4

7

14

856

809

808

883

810

858

857

135B

135C

h1

SF

SL

SJ

815C

808G

856

809

883

810D

858A

857

136

600MJ

600MK

1873

107X

992

991

1876

30

38

28

17

27

2

8

7

18

26

36

37

4

39

19

1

GB

A

1876

974

10

3

GC

B

GG

2 1

F G 1

FG

107AL

934B

3

5

1873

107AD

2

1

6

7

5

1

8 9 10

5 4 3

2

1

3

2

4

12 1

9

5

2

3

13

A

4

6

10

F

N

R

14

SA

2 1

2 1

7

991

2 1

107T

h4

2 c

SC

974

934

107

135

136

992

600DP

600DN

815C

42

7

34

52

53

45

49

50

10

C17

h5

2

1

3

3

2

1

SA

600Z

107AK

974

C10

1

6

7

12 24 30 36 48 60

1 13 25 31 39 49

FA

FB1

LC

1

6

7

600Z

107AK

974

1

2 1

2

LE

1 2

1

2

107U

992

60 48 36 30 24 12

49 39 31 25 13 1

LA

52

53

45

49

50

42

7

34

10

974

934

107H

135

136

992

600DP

600DN

815A

h2

SC

SB

7

34

52

53

10

12 24 30 36 48 60

1 13 25 31 39 49

LB

SS

6

3

EA

4 5

3 6

2 7

1 8

135D

135

CB

60 48 36 30 24 12

49 39 31 25 13 1

CB

EAB

5 4

6

7

3

2

8 1

7

34

52

53

6

3

934F

107H

135

136

6

7

9

CM

8 9 10

5 4 3

815

2

1

10

6

DW

8

7

9

DZ

1 2

5 4 3

6

7

3 2 1

2

1

136

135D

107

DR2

8 9 10

3 2 1

6 8

107AN

10 7

600MM

936

107AP

TF

3 1 2

600BF

SC

619

CCA

14

12

10

19

17

15

13

11

9

7

4

3

1

20

18

16

14

12

10

8

6

4

2

13

11

9

FUSE A7

FUSE A6

10 815A

FUSE A5

h3

A B

A B

A B

NG

MB1

600A

A B

600EZ

934A

SA

42

12 20 24 28 35 48

NH

CA

934F

1 13 21 25 29 37

12 20 24 28 35 48

1 13 21 25 29 37

42

A404930

Issue 1

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Section F

33 — 9

Powershift Gearbox — 6 Speed

Gearbox Solenoid Actuation h1

Transmission

Electrical Connections

1864

1861

1860

1862

1863

1866

1865

600MH

12

6

24

20

23

4

15

13

GC

B

Section F

33 — 9

9808/3280

FB1

SA

621

600DN

600DP

50

49

1865

1866

1863

1862

1860

1861

1864

19

16

15

13

11

6

51

FA

12 24 30 36 48 60

1 13 25 31 39 49

C10

1 11

600Z

1865

1866

1863

1862

1860

1861

1864

10 9 3 8 4 12

12 11 10 9

5 6

1 2 3 4

8

7

600Z

SC

LA

60 48 36 30 24 12

50

49

600DN

600DP

LC

1 2 3 4 5 6

12 11 10 9 8 7

1 11 10 9 3 8 4 12

49 39 31 25 13 1

19

16

15

13

11

6

51

1865

1866

1863

1862

1860

1861

1864

h2 h5

Purchased from www.WorkshopManuals.co.uk

F

1860

600BX

1

2

1 2

C30

2 1

T

E

1861

600BS

1

2

1 2

C20

I

2 1

U

1863

600CA

1

2

1 2

C60

J

2 1

W

1862

600BT

1

2

1 2

C70

2 1

V

SA

1865

600BZ

G

1

2

1 2

C40

2 1

Y

1866

600BY

H

1

2

1 2

C50

2 1

Z

6

1864

600ME

1

2

1 2

C90

2 1

X

A408630

Issue 1

Section F

33 — 10

LA

FA FB1

GC

9808/3280

LC

C10 www.WorkshopManuals.co.uk

F E I J

G H 6

A408660

Transmission

Electrical Connections

Section F

33 — 10

Powershift Gearbox — 6 Speed (cont’d)

Electrical Connections — Wires and Connectors

Gearbox Solenoid Actuation

For input controls see previous page.

Component Key

(solenoid activation)

:

The following key identifies the component connectors on the diagrams opposite. Note that the wires coloured green show the electrical ‘feed to earth’ for the gearbox mounted solenoids and gearbox ECU.

h1

Harness — 721/10937 Front console

h2

Harness — 721/10971 Link

h5

Harness — 721/10941 Gearbox

Note:

For harness drawings see

Section C

.

Connectors (h1)

GC

E.C.U. connector B

FA

h1 î h2

FB1

Earth point

Connectors (h2)

LA

h1

î h2

LC

h2

î h5

Connectors (h5)

C10

h5 î h2

C20

Gearbox solenoid U (labelled

E

)

C30

Gearbox solenoid T (labelled

F

)

C40

Gearbox solenoid Y (labelled

G

)

C50

Gearbox solenoid Z (labelled

H

)

C60

Gearbox solenoid W (labelled

I

)

C70

Gearbox solenoid V (labelled

J

)

C90

Gearbox solenoid X (labelled

6

)

Splices (h1)

SA

Splices (h2)

SC

Splices (h5)

SA

Earth Points

Faults may be caused by poor earth connections. Although earth connections are shown opposite, it must be remembered that the cab assembly is earthed via further earth strap and cable connections. For details of these connections see

Section C, Machine Earth Connections

.

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

35 — 1

www.WorkshopManuals.co.uk

Transmission

Fault Finding

Section F

35 — 1

Synchro Shuttle Gearbox

Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures.

Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.

A

If the transmission is noisy, start at check 1.

B

If the transmission is overheating, start at check 4.

C

If the transmission will not pull, start at check 12.

D

If there is no drive in one or both directions, start at check 17.

E

If the transmission is jumping out of gear, start at check 29.

F

If the transmission is sticking in gear, start at check 39.

G

If ratios are ‘crash changing’, start at check 41.

CHECK

1

Is there noise when selecting direction?

ACTION

YES: Check 3

NO: Check 2

2

Is there noise when running with direction selector in neutral and ratio selector in 1st?

3

Is there air in the hydraulic system?

4

5

6

7

Is the fluid level correct?

Are the oil passages restricted?

Is the suction strainer restricted?

Is pump pressure as specified?

YES: Check 9

NO: Check 19

YES: Continue running to expel air.

NO: Check 4

YES: Check 5

NO: Check level only when machine is cold and top-up as required.

YES: Clear the restriction.

NO: Check 6

YES: Remove and clean strainer.

NO: Check 7

YES: Check 9

NO: Check clutch pressure maintenance valve is free to operate.

8

When flow testing pump, is output low?

9

10

11

12

13

Does the noise continue when direction selector is in forward or reverse?

Is transmission misaligned?

Are the pump bushes worn?

Is the transmission not pulling in one direction only?

Is the transmission not pulling in both

Forward and Reverse?

YES: Renew pump.

NO: Check converter sprag clutch for wear or slip.

YES: Check 10

NO: Check 11

YES: Renew mountings and check position.

NO: Check ‘converter out’ pressure and flow.

YES: Renew

NO: Check converter for wear or cooler for restriction to flow.

YES: Check 16

NO: Check 13

YES: Stall test machine, Check 14.

NO: Check 16

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

35 — 2

www.WorkshopManuals.co.uk

Transmission

Fault Finding

Section F

35 — 2

Synchro Shuttle Gearbox (cont’d)

CHECK

14

15

16

31

32

Is ‘converter in’ pressure as specified?

Is pump being driven by converter?

Are clutch sealing rings damaged?

Are the dog gear teeth worn?

Are the selector rod detent springs broken?

ACTION

YES: Check 15

NO: Inspect converter relief valve for damage. Check cooler bypass valve pressure setting.

YES: Check pump pressure.

NO: Renew damaged parts.

YES: Tap pressure gauge into clutch feed lines to monitor pressure.

NO: Check clutch plates for damage.

17

18

19

Is there drive in one direction only?

Is the start switch in the run position and supplying current to the neutral start relay?

Is the fault only when the transmission is hot?

20

21

Is the noise a growl, hum or grinding?

Is the noise a hiss, thump or bumping?

22

Is the noise a squeal?

YES: Check free running gears for seizure.

NO: Check 23

23

Is the noise present when in neutral or when in gear? NEUTRAL: Check 24

IN GEAR: Check 27

24

Is the countershaft or its bearings worn or damaged?

YES: Renew damaged parts.

NO: Check 25

25

Is there excessive backlash in the gears?

YES: Check gears for damage or wear.

NO: Check 21

YES: Check bearings for damage or wear.

NO: Check 22

26

Is the mainshaft pilot bearing worn?

YES: Adjust by checking shaft end float.

NO: Check 26

YES: Renew.

NO: Check gear teeth for scuffing.

27

Is the mainshaft rear bearing worn?

28

29

Are the sliding gear teeth worn or damaged?

Are the selector forks loose?

YES: Check 19

NO: Check 18

YES: Check 19

NO: Rectify.

YES: Dismantle solenoid and check components.

NO: Check microswitches, relay and wiring loom.

YES: Renew.

NO: Check 28

YES: Renew gears.

NO: Check 29

YES: Tighten screws.

NO: Check 30

30

Are the selector fork pads or grooves in gears worn?

YES: Renew worn parts.

NO: Check 31

YES: Renew.

NO: Check 32

YES: Renew.

NO: Check 33

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

35 — 3

www.WorkshopManuals.co.uk

Transmission

Fault Finding

Section F

35 — 3

Synchro Shuttle Gearbox (cont’d)

CHECK

33

Are the selector rods worn or damaged?

34

Are the selector fork pads out of position?

35

Is there excessive end float in gears or shafts?

36

Is the synchroniser bronze worn?

37

Are steel chips embedded in the bronze?

38

Are the synchroniser components damaged?

39

Are the sliding gears tight on the splines?

40

Are chips wedged between splines of shaft or gear?

41

Are steel chips embedded in the bronze?

42

Are the synchroniser spring pins damaged?

43

Is the synchroniser bronze worn?

ACTION

YES: Renew.

NO: Check 34

YES: Reposition or renew (check interlock).

NO: Check 35

YES: Adjust.

NO: Check thrust washers and mating faces.

YES: Renew synchro pack.

NO: Check 37

YES: Continue using, chips will either embed below bronze or be rejected.

NO: Check 38

YES: Renew.

NO: Check free running gears for seizure or damage.

YES: Free or renew.

NO: Check 40

YES: Remove chips.

NO: Ensure that clutch is disengaged when dump pedal is pressed.

YES: Continue using, chips will either embed below bronze or be rejected.

NO: Check 42

YES: Renew synchro.

NO: Check 43

YES: Renew synchro.

NO: Check blocker pins.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

36 — 1

www.WorkshopManuals.co.uk

Transmission

Fault Finding

Section F

36 — 1

Synchro Shuttle Gearbox —

2/4 Wheel Drive Clutch

4WD CANNOT BE ENGAGED

In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures — eliminate the obvious:

1

Check that the transmission oil level is correct.

2

Check that the fuse for the 2/4WD circuit is intact.

3

Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact.

4

Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the

2WD position).

5

Check that the mainline pressure is correct (see ‘Low Mainline Pressure’).

6

Check that the pump flow rate is correct.

If the fault is not rectified after eliminating the obvious, check the following:

Possible Cause

7

Low mainline pressure

Remedy

7

Identify if the fault is related to the 2/4WD disconnect:

7.1

Disconnect the external pipework to the

2/4WD clutch. Cap and plug open orifices.

7.2

Check the mainline pressure — if the pressure is correct, the fault must be within the 2/4WD

(see step 8). If the reading is still low check the transmission in the normal manner.

8

Low mainline pressure (due to 2/4WD clutch):

8.1

2/4WD solenoid spool sticking.

8.2

2/4WD solenoid spool O-ring failed.

8.3

Clutch shaft sealing rings leaking.

8.4

Excessive clutch shaft end float.

8.5

Wrong type clutch piston fitted.

8.6

Clutch piston O-ring failed.

8

Rectify fault:

8.1

Strip, clean and re-assemble solenoid valve, renew valve if required.

8.2

Renew O-ring.

8.3

Renew clutch shaft sealing rings.

8.4

Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in)

8.5

Fit correct type clutch piston (ie, without bleed hole).

8.6

Replace clutch piston O-ring.

9

Defective 2/4WD clutch:

9.1

Worn friction/counter plates

9.2

Mechanical failure of 4WD unit

9.3

Incorrect clutch pack end float.

9

Rectify fault:

9.1

Inspect friction/counter plates, renew as required.

9.2

Strip and inspect 4WD unit. Check that the electrical and hydraulic circuits are functioning correctly.

9.3

Measure clutch pack end float (should be 1.0 to

2.3 mm). Correct as required.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

36 — 2

www.WorkshopManuals.co.uk

Transmission

Fault Finding

Section F

36 — 2

Synchro Shuttle Gearbox —

2/4 Wheel Drive Clutch (cont’d)

2WD CANNOT BE ENGAGED

No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below.

Possible Cause

10

Incorrect type of solenoid valve fitted.

Remedy

10

Check solenoid.

Note:

Powershift and Syncro Shuttle machines have different types of solenoid — check parts list.

11

Non-return valve faulty (noticeable because 2WD cannot be engaged).

11

Check the non-return valve.

12

2/4WD solenoid permanently energised.

12

Check the 2/4WD relay and select switch, replace as necessary.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

40 — 1

www.WorkshopManuals.co.uk

Transmission

Fault Finding

Section F

40 — 1

Powershift Gearbox

Introduction

The fault finding procedures are given in the form of flow charts. There are a number of charts, each one dedicated to a particular fault. The charts are designed to identify possible causes by performing checks and where applicable, specific tests on the gearbox. Having identified a cause the suggested remedy is given. The charts are designed to identify causes through a process of elimination, starting with the simplest, most easily rectified faults.

*

Gearbox faults may be caused by faulty electrical connectors or components as indicated in the fault finding charts. Full explanations of the relevant electrical systems for both 4 speed and 6 speed (Shiftmaster) gearboxes are given in

Electrical Connections

.

Due to the time and effort involved in removing, dismantling, assembling and replacing a gearbox, it is recommended that fault finding procedures are carried out until a fault can be identified with a good degree of certainty.

Full details of the test procedures referred to in the charts are given in

Service Procedures, Powershift Gearbox.

Fault Finding Charts:

Chart A

— Machine drives but lacks power in all gears.

Gearbox oil may also be overheating.

Chart B

— Machine does not drive in any gear.

Chart C

— Some gears fail to engage or lack power. 4WD fails to engage.

Chart D

— (6 speed gearbox only) Shiftmaster fails to function normally — fails to autoshift — shifts at incorrect road speed.

Note:

4th, 5th and 6th gears utilise clutches used for 1st,

2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage, check that the lower 3 gears function correctly before investigating a possible Shiftmaster fault. See

Fault Finding

Chart C.

Chart E

— Gearbox oil overheats

Chart F

— External oil leakage

Chart G

— Noisy operation

Further Fault Finding Information

Gearbox Oil Contaminated with Water

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

www.WorkshopManuals.co.uk

Powershift Gearbox

Chart A — Machine drives but lacks power in all gears. Gearbox oil may also be overheating.

START

Is gearbox oil level low?

YES

YES

NO

Is gearbox oil the correct type and free from contamination?

YES

Carry out a Torque Converter Stall Test in all gears. Are all the stall speeds outside specifications?

NO

Carry out Mainline Oil Pressure Test

Is mainline oil pressure correct?

NO

Check condition of pressure maintenance valve. Clean or renew as applicable.

Check for signs of excessive external oil leakage.

Carry out Mainline Oil Pressure and

Flow Tests

Is mainline oil pressure /flow correct?

NO

Remove and dismantle gearbox.

Check condition of pump, casings for internal/external leakage. The clutches will have been slipping due to low oil pressure — dismantle all clutches and renew as required.

YES

YES

YES

YES

Top up oil level

Check reason for contamination.

Rectify as applicable Drain and flush oil, see Flushing the Gearbox Oil.

Check the operation of the parking and service brakes.

NO

Are all the stall speeds too low?

YES

Repair the engine as applicable.

NO

Is the engine performance normal?

See Checking the Engine Power.

YES

Torque converter reaction member clutch slipping. Remove the gearbox and renew the torque converter.

Carry out Torque Converter In

Pressure Test. Is torque converter in pressure correct?

YES

NO

Check condition of torque converter relief valve.

Clean or renew as applicable.

Too high?

YES

Cooler lines restricted or blocked. Oil cooler blocked.

Carry out Torque Converter Out

Pressure Test. Is torque converter out pressure correct?

NO

YES

It may be that another fault may have been overlooked. Go back to the start of the fault finding and re-check.

Too low?

YES

Cooler lines or cooler leaking. Internal leakage. Remove the gearbox, torque converter housing and pump, check all sealing faces for damage.

A396280

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Powershift Gearbox

Chart B — Machine does not drive in any gear.

START

Is gearbox oil level low?

NO

Are the park brake and transmission dump switches working correctly?

YES

Is the gear selection column switch working correctly. See Powershift

Electrical System Tests.

NO

Carry out Mainline Oil Pressure Test

Is mainline oil pressure correct?

NO

Check condition of pressure maintenance valve. Clean or renew as applicable.

Check for signs of excessive external oil leakage.

Carry out Mainline Oil Pressure and

Flow Tests

Is mainline oil pressure /flow correct?

NO

Remove and dismantle gearbox.

Check condition of pump, casings for internal/external leakage. Check pump drive dogs on torque converter are undamaged.

YES

NO

NO

YES

YES

Top up oil level.

Renew switch or repair wiring as applicable.

Renew switch or repair wiring as applicable.

Carry out Torque Converter In

Pressure Test

Is torque converter in pressure correct?

YES

Are the clutch control solenoids working? Check control valve solenoids for correct resistance and wiring continuity — check forward and reverse solenoids first.

YES

6 Speed — Is the gearbox ECU connected correctly?

4 Speed — Are the Powershift relays connected correctly?

YES

6 Speed — Renew the ECU.

4 Speed — Renew the relays as applicable.

NO

NO

NO

Check condition of torque converter relief valve.

Clean or renew as applicable.

Renew solenoid or repair wiring as applicable.

Clean connectors and fit securely.

A396290

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Powershift Gearbox

Chart C — Some gears fail to engage or lack power. 4WD fails to engage.

START

Are the gear selection column/4WD switches working correctly. See

Powershift Electrical System Tests.

YES

Are the relevant the clutch solenoids working? Identify the applicable solenoids and check for correct resistance and wiring continuity.

YES

NO

NO

Carry out Individual Clutch Pressure

Tests. Are the relevant clutch pressures correct?

NO

Are the oilways clear at the control valve manifold and casing? —

Remove the manifold and check. See

Removing the Control Valves.

YES

Clutch Leakage: Remove and dismantle gearbox. Check condition of clutch piston seals, ball valves and housings. Check shaft sealing rings for wear or damage.

YES

NO

Renew applicable switch or repair wiring as applicable.

Are the solenoids or associated wiring faulty.

NO

6 Speed — Is the gearbox ECU connected correctly?

4 Speed — Are the Powershift relays connected correctly?

YES

6 Speed — Renew the ECU.

4 Speed — Renew the relays as applicable.

Clutch failure, jammed pistons or blocked oil ways: Remove and dismantle gearbox. Clear oilways, renew clutches as applicable.

YES

NO

Clear debris from ports. Replace valve manifold. If fault is cleared, flush gearbox oil. See Flushing the Gearbox

Oil.

Renew applicable solenoid or repair wiring as applicable.

Clean connectors and fit securely.

A396300

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Powershift Gearbox

Chart D — (6 speed gearbox only) ShiftMaster fails to function normally — fails to autoshift — shifts at incorrect road speed.

START

Are the gear selection column switches, kickdown and throttle switches working correctly?

YES

*

Is the speed sensor operating?

See Service Procedures — Powershift

Gearbox, Speed Sensor.

YES

Is the gearbox ECU connected correctly?

YES

*

Renew the ECU.

See Service Procedures,

Powershift Gearbox, Electronic

Control Unit.

NO

NO

NO

*

Renew the switch or repair wiring as applicable.

Renew sensor or repair wiring as applicable.

Clean connectors and fit securely.

Use ShiftMaster Diagnostics software to check ECU inputs and outputs. See

Service Procedures, Powershift

Gearbox, Diagnostics User Guide.

A396310

Note:

4th, 5th and 6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or

6th gears fail to engage, check that the lower 3 gears function correctly before investigating a possible ShiftMaster fault. See

Fault Finding Chart C

.

*

The simplest and best way to fault find the 6 speed gearbox electrical system, (including the

ECU) is by using ShiftMaster Diagnostics software and a laptop PC. See

Diagnostics User

Guide

. This diagnostics system enables the engineer to quickly identify faults with specific electrical circuits or devices. The devices electrical connections, locations and wire identifications are given in

Electrical Connections — Powershift Gearbox — 6 Speed

. See also

Section C — Harness Data

.

‘Limp Modes’

When applicable the ShiftMaster ECU provides restricted or modified gearbox operation if faults are detected by the ECU. Typical ‘Limp Mode’ forms of operation are:

Limp Mode 1

Machine autoshifts at different road speeds than normal.

2 Beeps at power-up

.

Possible Reason

Internal ‘Setup Data’ ECU fault.

If on power-up the ECU detects an internal fault with its ‘Setup Data’ it will revert to use of a default set of values.

Limp Mode 2

Machine remains in neutral at all times.

1 Beep at power-up

.

Error with ECU ‘Application Software’.

If on power-up the ECU detects an internal fault with its ‘core operating software’ it will prevent operation of the gearbox.

Limp Mode 3

Only 1st, 2nd, and 3rd gears available.

Machine will not autoshift

.

Error reading transmission speed.

If the ECU does not detect any input from the speed sensor it will prevent selection of any gear above 3rd.

Limp Mode 4

Machine holds a gear.

Repeating beeps until ECU power is reset

.

Error reading transmission speed.

If the ECU detects an error with the speed sensor whilst operating it prevents autoshifting.

Note:

On power-up the ECU will normally sound 3 beeps. These beeps can be masked by other audible warnings on start up.

Purchased from www.WorkshopManuals.co.uk

Powershift Gearbox

Chart E — Gearbox oil overheats

www.WorkshopManuals.co.uk

START

Is the gearbox oil cooler heat exchanger matrix clogged with dirt/chaff?

YES

Is gearbox oil level incorrect (too low or too high)?

NO

YES

Is gearbox oil the correct type and free from contamination, especially water contamination?

NO

Are the cooler lines kinked, or trapped?

YES

YES

NO

Is the machine being operated correctly — in the correct gear range?

NO

YES

Carry out Torque Converter Out

Pressure/Flow Test. Is the pressure correct?

YES

Is oil flow correct?

YES

NO

NO

Remove gearbox. Check condition of pump, casings for internal/external leakage. Inspect clutches for signs of jammed pistons. Repair clutches as applicable.

Clean the matrix.

Adjust oil to correct level.

Check reason for contamination.

Rectify as applicable. Drain and flush oil, see Flushing the Gearbox Oil.

Rectify routing/renew hoses as applicable

Educate operator.

Check condition of torque converter relief valve.

Clean or renew as applicable.

YES

Is the cooling circuit restricted or blocked internally? Remove cooler, check lines and cooler for internal blockages.

NO

YES

Rectify as applicable.

A396320

Purchased from www.WorkshopManuals.co.uk

Powershift Gearbox

Chart F — External oil leakage

START

Is the oil leaking from the gearbox or from another source? Remember that the main machine hydraulic pump is mounted on the gearbox. Oil leakage from inside the torque converter housing may be engine oil.

YES

NO

Is gearbox oil level too high?

YES

NO

Is oil leaking from external, plugs, adaptors, filter, pipes and hoses on the gearbox and cooling circuit?

NO

YES

Is oil leaking from the solenoid control valve manifold/solenoid valve stem?

YES

NO

Is oil leaking between the torque converter housing to front case joint?

YES

NO

Carefully check casings for signs of damage. If damage is evident, remove the gearbox and renew components as required.

www.WorkshopManuals.co.uk

Rectify as applicable.

Drain oil to correct level.

Check oil for water contamination.

Rectify as applicable.

Remove valve manifold, check sealing faces for damage. Renew gaskets, solenoids and components as applicable.

Remove gearbox. Remove the torque converter housing. Check the sealing faces for signs of damage. Rectify as applicable. Re-seal casings, See

Powershift Gearbox — Assembly step 10.

A396330

Purchased from www.WorkshopManuals.co.uk

Powershift Gearbox

Chart G — Noisy operation

START

Is gearbox oil level low?

NO

YES www.WorkshopManuals.co.uk

Top up oil level.

Is gearbox oil the correct type and free from contamination?

NO

Carry out a Lubrication Pressure

Test.

Is the pressure low?

NO

NO

YES

Check reason for contamination.

Rectify as applicable Drain and flush oil, see Flushing the Gearbox Oil.

Carry out Torque Converter Out

Pressure Test. Is the pressure correct?

NO YES

Check the condition of the torque converter relief valve. Make sure that the cooler lines are not restricted.

Rectify as applicable.

Remove and dismantle gearbox.

Check all components for signs of wear or damage, especially shaft seals and bearings. Rectify as applicable.

A396340

Purchased from www.WorkshopManuals.co.uk

Section F

40 — 9 Fault Finding

Section F

40 — 9

Powershift Gearbox

Gearbox Oil Contaminated with Water

Carefully inspect the gearbox oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum permissible water content of the oil is 0.10% .

If the gearbox oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before remedying, thoroughly investigate and rectify the cause of the water contamination.

Note: The correct gearbox oil is given in Section 3,

Service Capacities and Lubricants

.

Possible Cause

1

Water ingress during filling/topping up.

2

3

Missing/incorrect dipstick, damaged filler tube.

Machine operated in deep water.

Remedy

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

Renew missing/incorrect/damaged components.

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

4

Gearbox casings damaged.

5

Gearbox oil circuit pipes/hoses damaged.

Inspect, renew damaged components.

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

Inspect, renew damaged components.

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

Gearbox faults caused typically by water contamination and other factors related to the gearbox oil:

Fault

1

Pressurisation of gearbox casing — Dipstick blows out/oil leaking from dipstick tube.

Possible Cause

Water in oil combined with heat from torque converter causes steam.

Remedy

Replace/renew dipstick.

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

2

Clutch Failure — Friction Lining

Separation.

Gearbox over filled with oil.

Water ingress.

Drain the oil level to the correct level, see

Routine Maintenance — Checking

Transmission Oil Level

.

Renew friction plates.

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

3

Badly worn/noisy bearings.

Overheating transmission oil.

Water ingress.

Insufficient lubrication.

See

Fault Finding — Overheating

.

Fit new bearings.

Carry out flushing procedure.

Refill with the correct oil, see Section 3,

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

50 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

50 — 1

Front Axle — SD55, SD70

Renewing the Pinion Oil Seal

The pinion oil seal

3

may be renewed without removing the axle from the machine.

!

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.

GEN-001

1

Rem o ve t he ro ad w heels and unc o up le t he ax le propshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft

4

and nut

2

with a scriber.

2

Using Service Tool 892/00812, remove the drive yoke

1

together with its stake nut

2

.

3

Remove the seal

3

and fit a new one. Be sure not to damage the seal housing. Pack between the lips of the new seal with grease before fitting.

4

Check the sealing surface on the yoke for wear or damage. renew the yoke if necessary.

5

Fit the yoke and temporarily fit the old stake nut

2

.

Tighten the nut with a torque wrench, aligning the scriber marks. Note the tightening torque required.

6

Remove and discard the old nut. Fit a new nut and tighten to the torque determined at step 5.

6.1

Measure the rolling torque. The reading should be

0.5 to1Nm (0.37 to 0.74lbf ft; 0.05 to 0.1kgf m) more than that recorded in Step 1 (see Note).

6.2

If necessary, progressively torque tighten the nut to a maximum of 300 Nm (221 lb f ft ) t o ac hieve correct rolling torque.

Note:

If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in step 1 by 1Nm (0.74 lbf ft;

0.1 kgf m) or more, or a minimum torque of 250 Nm (184 lbf ft) can not be achieved then the pinion assembly must be rebuilt using a solid spacer, see the apprpriate axle assembly procedure.

6.3

Stake the nut using a square ended staking tool.

7

Refit the roadwheels and couple the propshaft.

9803/3280

Typical Axle Shown

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

51 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

51 — 1

Rear Axle — SD80, PD70

Renewing the Pinion Oil Seal

The rear axle pinion oil seal is renewed using the same procedure as

Front Axle SD55, SD70

but note the following:

The rear axles are fitted with a brake disc/drive flange in place of the yoke on front axles. For the brake disc removal procedure see

Section G, Brakes, Service Procedures

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

52 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

52 — 1

Rear Axle — SD80, PD70

Brakes — Testing for Piston Seal Leakage

See

Section G, Brakes, Service Procedures

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

55 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

55 — 1

G

K

J

H

E

D

F

9803/3280

S266880

A

B

C

L

Purchased from www.WorkshopManuals.co.uk

A396910

Issue 1

Section F

55 — 2

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

55 — 2

Synchro Shuttle Gearbox

Torque Converter Stall Test

Ensure that the engine and transmission are at normal working temperature. Run engine at maximum speed and check the

No Load Speed (High Idle Speed — U.S.A)

. See

Engine Technical Data for correct figure; adjust if necessary.

Apply parking brake and footbrake firmly, select 4th Speed

Forward and open throttle fully. Engine speed should be as specified at

Torque Converter Stall

in Transmission

Technical Data. Select Reverse and repeat test.

Note:

When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational.

Alternatively, disconnect the switch at the park brake.

DO NOT

stall the converter for longer than 10 seconds or the transmission fluid will overheat.

If engine speeds are higher than the stated figures check the transmission for clutch slippage or internal leakage.

If engine speeds are below the stated figures either the engine is losing power and should be serviced/overhauled or the torque converter reaction member clutch is slipping. To check the engine, select Neutral, open throttle fully and operate an excavator service to ‘ blow off’ the main relief valve. Engine speed should fall to slightly above the

Maximum Governed Speed

(see Engine Technical Data). If engine speed is correct the torque converter is faulty.

Note: Maximum Governed Speed

is a datum figure only. It cannot be adjusted or checked with the engine installed in the machine.

Pressure and Flow Test

Note:

The tests must be carried out only in the following order, step by step.

!

WARNING

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

Trans 1-2

1

Stop engine, remove transmission filter and filter head adapter. Fit adapter

A

(892/00920) into the gearbox casing. Fit test adapter

B

(892/00301) and secure with adapter

C

(892/00302). Connect flowmeter

D

(892/00229) as shown and connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector

E

(see Service

Tools, Section 1).

2

Start engine and run at 1000 rev/min. The flowmeter will show the

Pump Flow

which should be as shown in

Technical Data. A low reading indicates a worn pump or blocked suction strainer. The pressure gauge will show the

Main Line Pressure

(see Technical Data). A low reading can be caused by either a faulty pressure maintenance valve or a worn pump. A high reading indicates a faulty pressure maintenance valve or, if the pump flow is low, the oil cooler may be blocked.

3

Stop engine, remove flow test adapters and refit filter.

Connect pressure gauge and flowmeter into converter out line as shown at

F

. Run engine at 1000 rev/min with transmission in Neutral and note

Converter Out

Pressure

and

Oil Cooler Flow

, which should be as shown in Technical Data. A high pressure together with low flow could be caused by a blocked oil cooler. (See also check 7.)

4

With parking brake and footbrake firmly applied, select

Forward and check flow reading, which should not fall by more than 4.5 litres (1 UK gal; 1.2 US gal) per minute. A low reading indicates a high leakage rate in that particular clutch, which could be caused by worn or broken piston seals or shaft sealing rings. Select

Reverse and repeat the test.

5

If the clutch leakage rate is high, the

Clutch Pressures

may be checked by connecting the pressure gauge into ports

G

and

H

and repeating test

4

. A low reading (see

Technical Data) would confirm a high leakage rate in the particular clutch selected.

6

Stop engine, connect the pressure gauge into port

J

in the transmission, and fit a load valve

L

into the converter out line (see note).

Note:

Make sure that the load valve

L

has been screwed fully out before starting the engine, otherwise the converter seals will be damaged.

Start engine, run at 1000 rev/min and slowly screw down the load valve whilst observing the gauge reading, which should rise to the setting of the

Converter Relief (Safety) Valve

(see Technical Data).

DO NOT

allow the pressure to exceed 10.3 bar (150 lbf/in 2 ) or damage to the converter seals will be caused.

If the reading is higher than specified, the relief (safety) valve must be faulty. A low reading indicates a faulty relief (safety) valve, leaking converter ‘piston ring’ type seal or leaking pump seal.

7

Stop engine and connect pressure gauge and flowmeter into return line from oil cooler to transmission as shown at

K

. Start engine, and with transmission in

Neutral check flowmeter reading, which will show the

Cooler Flow Rate

(see Technical Data). The pressure gauge will show the

Lubrication Pressure

(see

Technical Data). Low flow and pressure readings could indicate a blocked oil cooler.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

57 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

57 — 1

Synchro Shuttle Gearbox

Forward/Reverse Solenoid Control Valve

Dismantling

Unscrew the knurled nut

2

and remove ‘O’ ring

3

, withdraw the solenoid

4

and ‘O’ ring

5

.

Hold the solenoid valve body

6

in a vice, using the spanner flats

A

, remove spindle

7

and ‘O’ ring

8

.

Pull out actuating pin

9

, spring

10

, spring retainer

11

, and spool

12

.

Inspect the spool and spool bore for signs of wear, nicks scratches etc.

Assembling

Assembly is reversal of the dismantle procedure.

Renew all ‘O’ rings.

Lightly lubricate all parts with clean transmission fluid before assembling.

Check that the flying leads are secure and that the connectors are intact.

Torque Settings

Item

2

Nm kgf m lbf ft

10 to 15 1 to 1.5

8 to 10

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

63 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

63 — 1

B

B

2 6

1

A

C

D

C

D

X

2

3

5

4

9803/3280

Purchased from www.WorkshopManuals.co.uk

A405990

Issue 1

Section F

63 — 2

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

63 — 2

Powershift Gearbox

Gearbox Hydraulic Pump —

Removal and Replacement

The gearbox hydraulic pump is located at the input end of the gearbox. The gearbox must be removed from the machine to enable removal and replacement of the pump.

Removal

1

Remove the gearbox from the machine, see

Powershift

Gearbox Removal and Replacement

.

IMPORTANT NOTE: After removing the gearbox DO NOT

REMOVE THE TORQUE CONVERTER HOUSING

1

from the gearbox. A simple service tool (

A

) must be manufactured to enable the pump assembly to be removed. See

Transmission, Service Tools

for details.

2

Undo the 4 fixing bolts

2

. Discard the sealing washers

3

.

3

Using a set of M10 x 1.5 taps carefully tap the 2 holes

B

in the pump assembly

6

. Start with the taper tap (be sure not the damage the tapped holes in the gearbox front case beneath) and finish with the plug tap. Ensure that the thread is at least 35 mm (1.38 in) deep and both the pump body and stator are threaded. Be sure to remove ALL swarf before proceding.

4

Screw in a 250 mm (10 in) length of M10 threaded rod

C

into each hole

B

. Position the reaction bar

A

as shown. Progressively screw down the M10 nuts

D

to withdraw the pump assembly from its housing.

5

Remove and discard the pump sealing ring

4

. Remove and discard the ‘O’ ring

5

from the pump locating bore in the housing

1

.

Note:

The pump should be dismantled and inspected, see

Powershift Gearbox — Inspection

. Note that a pump which is badly worn or damaged may have caused further damage to the gearbox, see

Powershift Gearbox — Dismantling

.

Replacement

1

Fit a new ‘O’ ring

5

to the locating bore inside the housing

1

. Lightly oil the ‘O’ ring.

2

Make sure that the pump is fitted with a new oil seal, see

Powershift Gearbox, Inspection, step 4

.

Fit a new sealing ring

4

. Locate the pump over the input shaft aligning the bolt holes. Apply JCB Threadlocker and Sealer to bolts

2

. Fit the bolts together with new sealing washers

3

. Progressively torque tighten the bolts to 28 Nm (20 lbf ft).

3

Pour some clean, new, oil into the pump at position

X

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

64 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

64 — 1

Powershift Gearbox

Suction Strainer — Removal and Replacement

Removal

The suction strainer is located inside the gearbox front case.

Access is gained by removing the 4WD clutch assembly.

1

Park the machine on level ground, apply the parking brake and chock the wheels.

2

Allow transmission oil to cool and then drain the oil, see

Powershift Gearbox, Changing the Oil, Routine

Maintenance.

3

Disconnect the propshaft from the 4WD unit, see

Propshaft, Removal and Replacement.

4

Remove the 4WD unit, see

Powershift Gearbox,

Dismantling Step 6 — Remove the 4WD Clutch

Assembly

.

5

Using a 13 mm ring spanner, reach inside the casing and undo the 2 suction strainer retaining bolts

A

. Be sure to retrieve the bolts from inside the gearbox.

6

Push the suction strainer

B

away from you (towards the rear of the gearbox) to disengage it from the gearbox casing. Remove the strainer via the 4WD aperture.

7

Make sure that the gasket

C

is retrieved. Discard the gasket.

8

Clean the suction strainer by flushing with a solvent cleaner. Inspect the strainer mesh for tears or splits.

Renew the suction strainer if the mesh is damaged.

Replacement

Replacement is the reverse of the removal sequence but note the following:

1

Fit a new gasket

C

.

2

Make sure that no loose components or debris have been left inside the gearbox casing.

3

Before replacing the 4WD assembly make sure that all traces of gasket or gasket compound have been removed from the mating faces, see

Powershift,

Gearbox, Inspection

.

A

B

9803/3280

C

A

A403940

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

65 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

65 — 1

Powershift Gearbox

Torque Converter Stall Test

The purpose of the stall test is to check the performance of the transmission by ‘stalling’ the torque converter. This is the point at which, due to torque applied by the engine the torque converter stops transmitting drive to the gearbox.

The engine speed at which ‘stalling’ occurs is compared to speeds recorded for a machine in normal condition (given in

Technical Data

). Abnormal stall speed results can be used to identify a number of possible faults with the transmission, typically gearbox hydraulic and clutch faults.

Note:

DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat. Make sure that the oil level is correct and at normal operating temperature.

Before completing the following test, remove the transmission dipstick. If there is any sign of smoke emitting from the dipstick tube STOP THE TEST IMMEDIATELY and dismantle the transmission for servicing.

By performing the tests in the first 3 gears in forward and reverse we can see from the tables below that all the clutches in the gearbox will be engaged, ensuring faults will be easy to identify. Draw a table as shown so that you can record the results.

Stall Test Results — 6 Speed Powershift

Gear Clutches engaged

Forward Rev/min Reverse Rev/min

1st

2nd

3rd

X,Z

T,Z

U,Z

W,Z

V,Z

W,Y

Note:

When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational.

Alternatively, disconnect the switch at the park brake.

3

Select 1st speed forward drive and open throttle fully.

Record the engine speed from the tachometer. Repeat the test for 2nd and 3rd speed forward and record the readings.

4

Repeat step

3

except this time select 1st, 2nd and 3rd gear reverse drive respectively. Record the readings.

5

All recorded readings should be as specified at

Torque

Converter Stall

in Transmission Technical Data.

Key to Clutches

T

— Forward low ratio clutch pressure

U

— Forward high ratio clutch pressure

V

— Reverse high ratio clutch pressure

W

— Reverse low ratio clutch pressure

X

— 6 speed clutch pressure (6 speed gearbox only)

Y

— Mainshaft clutch pressure

Z

— Layshaft clutch pressure

Stall Test Results — 4 Speed Powershift

Gear Clutches engaged

Forward Rev/min Reverse Rev/min

1st

2nd

3rd

T,Z

U,Z

T,Y

W,Z

V,Z

W,Y

1

Ensure that the engine and transmission are at normal working temperature (the transmission oil must be above 50°C). Run engine at maximum speed and check the

No Load Speed (High Idle Speed — U.S.A).

See

Engine Technical Data for correct figure; adjust if necessary.

2

Apply parking brake and footbrake firmly. If necessary, set the machine against a fixed obstruction.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

65 — 2

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

65 — 2

Powershift Gearbox

Torque Converter Stall Test, cont’d

Interpreting the Test Results

If all the engine speeds are below the stated figures either the engine is losing power and should be serviced/overhauled or the torque converter reaction member clutch is slipping. To check the engine, select

Neutral, open throttle fully and operate an excavator service to ‘blow off’ the main relief valve. Engine speed should fall to slightly below the

Maximum Governed Speed

(see

Engine

Technical Data

). If engine speed is correct the torque converter reaction member clutch is slipping.

If all the engine speeds are higher than the stated figures in all gears the torque converter safety relief valve may be faulty. Alternatively there may be internal oil leakage.

If engine speeds are higher than the stated figures in some gears, check the transmission for clutch slippage or internal leakage. Look at the example below and see how the results can be used to isolate a suspect clutch.

Stall Test Results — 6 Speed Powershift

Gear Clutches engaged

Forward Rev/min Reverse Rev/min

1st

2nd

3rd

X,Z

T,Z

U,Z

1990

2060

1985

W,Z

V,Z

W,Y

1980

1975

1990

In the example shown, we can see that the engine speed is abnormally high when 2nd gear forward drive is selected, indicating a slipping clutch, possibly

T

or

Z

. We can now use the results to determine which clutch is at fault.

From the table we can see that there is no problem with clutch

Z

since it is engaged in other gears, the stall speeds for those gears are normal. This indicates that clutch

T

is slipping.

Clutches may be slip for several reasons. Hydraulic leakage is possible and this can be confirmed by carring out a pressure test, see

Pressure Testing — Individual Clutches

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

66 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 1

Powershift Gearbox

Pressure and Flow Testing

Y

A

J

Z

T

U

L

S

X

9803/3280

M

F

B

W

V

C

Purchased from www.WorkshopManuals.co.uk

A396470

Issue 1

Section F

66 — 2

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 2

Powershift Gearbox

Pressure and Flow Testing

Before completing any of the transmission pressure/flow tests, make sure that the oil level is correct and at normal operating temperature (not less than 50°C).

All gauges etc used in the following pressure/flow tests are shown in

Service Tools

.

!

WARNING

Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil 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 oil. If hydraulic oil penetrates your skin, get medical help immediately.

HYD 1-1

!

WARNING

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

Trans 1-2

!

WARNING

DO NOT go underneath the machine with the engine running. Switch off the engine, apply the parking brake and chock both sides of all wheels before going underneath the machine.

Trans 2-1

!

WARNING

If a 4 wheel drive machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only one pair of wheels is raised, the machine could still drive through the other axle.

Trans 2-2/2

!

WARNING

Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine.

INT-3-1-16

TEST POINTS

A

— Mainline pressure

B

— Converter inlet/converter relief valve pressure

C

— Converter outlet pressure

F

— Pump flow (remove filter and fit adapters)

J

— Lubrication pressure

Clutches:

S

— 2/4 wheel drive clutch pressure

T

— Forward low ratio clutch pressure

U

— Forward high ratio clutch pressure

V

— Reverse high ratio clutch pressure

W

— Reverse low ratio clutch pressure

X

— 6 speed clutch pressure (6 speed gearbox only)

Y

— Mainshaft clutch pressure

Z

— Layshaft clutch pressure

Other items:

L —

Torque converter relief valve

M —

Pressure maintenance valve

Test Procedures

Pump Flow

Mainline Pressure

Converter In Pressure

Converter Relief (Safety) Valve Pressure

Converter Out Pressure/Oil Cooler Flow Rate

Lubrication Pressure

Clutches:-

Isolating a Suspect Clutch

Individual Clutch Leakage Test

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

66 — 3

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 3

Powershift Gearbox

Pressure and Flow Testing

A

9803/3280

B

Purchased from www.WorkshopManuals.co.uk

A396990

Issue 1

Section F

66 — 4

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 4

Powershift Gearbox

Pressure and Flow Testing, cont’d

Pump Flow

1

Stop engine, remove the gearbox oil filter and fit adapter

X

(460/15708) into the gearbox casing.

Connect flowmeter

W

(892/00268).

2

Start engine and run at 1000 rev/min. With the transmission in neutral the flowmeter will show the

Pump Flow

which should be as shown in

Technical

Data

. A low reading indicates a worn pump or blocked suction strainer.

3

Repeat step

2

and note gauge readings with engine running at 2000 rev/min.

4

Stop engine and remove test adapters, refit filter.

Mainline Pressure

1

Stop engine, connect a 0-20 bar (0-300 lbf/in 2 ) pressure gauge to test connector

A

.

2

Start engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show the

Main Line Pressure

which should be as shown in

Technical Data

. A low reading can be caused by either a faulty pressure maintenance valve or a worn pump. A high or low reading may indicate a faulty pressure maintenance valve.

3

Repeat step

2

, with engine running at 2000 rev/min note gauge readings which should be as shown in

Technical Data

.

4

Stop engine and remove test gauge.

Converter In Pressure

Note that the converter in pressure is affected by the torque converter relief valve operation. Before carrying out tests check the operation of the relief valve (see

Converter Relief

(Safety) Valve Pressure

).

1

Stop engine, connect a 0-20 bar (0-300 lbf/in 2 ) pressure gauge to test point

B

.

2

Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show

Converter In Pressure

which should be as shown in

Technical Data. A high or low reading could indicate a faulty converter relief valve.

3

Remove pressure test gauge.

W

X

9803/3280

A396980

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

66 — 5

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 5

Powershift Gearbox

Pressure and Flow Testing

J

C

K

B

9803/3280

P

Purchased from www.WorkshopManuals.co.uk

A397000

Issue 1

Section F

66 — 6

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 6

Powershift Gearbox

Pressure and Flow Testing, cont’d

Converter Relief (Safety) Valve Pressure

The purpose of the torque converter relief valve is to protect the torque converter from excessive oil pressure. Excessive oil pressure can be generated when the transmission oil temperature is below 50°C and/or the engine is run at over

2000 rev/min. In this event the relief valve opens and returns oil directly to the transmission sump, bypassing the torque converter, cooler and clutch lubrication circuits, protecting against damage due to excessive pressure. For this reason it is essential that the transmission oil is above 50°C and the engine is run between idle and 1000 rev/min when testing the relief valve.

1

Connect a 0-20 bar (0-300 lbf/in

2

) pressure gauge to test point

B

.

2

Fit a load valve

P

into the converter out line.

!

CAUTION

Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Failure to do this could damage the pump.

HYD 4-4/1

DO NOT

allow the pressure to exceed 8.3 bar (120 lbf/in

2

) or damage to the converter seals will be caused.

3

Start the engine and run at 1000 rev/min. With the transmission in neutral, slowly screw down the load valve

P

whilst observing the gauge reading which should rise to the

Converter Relief (Safety) Valve

setting as specified in Technical Data.

Note that the gauge pressure will fall once the valve has opened. This is normal relief valve operation and does not indicate a fault. If necessary reset the load valve

P

and perform the test again, watching the pressure gauge carefully.

4

If the converter relief valve opens at a pressure higher than specified then the valve is faulty. A low opening pressure indicates a leaking pump to casing seal or a faulty converter relief valve.

5

Stop engine, remove test gauges and load valve. Refit hoses to original position.

Converter Out Pressure/Oil Cooler Flow Rate

Note that the converter out pressure and oil cooler flow rate are affected by the torque converter relief valve operation.

Before carrying out tests check the operation of the relief valve (see

Converter Relief (Safety) Valve Pressure

.

1

Stop engine, connect a 0-20 bar (0-300 lbf/in 2 ) pressure gauge and flowmeter into the converter out line as shown at

C

and

K

respectively.

2

Run the engine at 1000 rev/min with transmission in neutral. The pressure gauge indicates the

Converter

Out Pressure

and the flowmeter indicates the

Oil

Cooler Flow Rate

, both readings should be as specified in

Technical Data

. A high pressure together with low flow could be caused by a blocked oil cooler or internal leakage.

3

Repeat step

2

, with engine running at 2000 rev/min note gauge readings which should be as shown in

Technical Data

.

4

Stop engine, remove test gauges and refit hoses to original position.

Lubrication Pressure

Note that the lubrication pressure is affected by the torque converter relief valve operation. Before carrying out tests check the operation of the relief valve (see

Converter Relief

(Safety) Valve Pressure

.

1

Stop engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as shown at

J

.

2

Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will indicate the

Lubrication Pressure

which should be as specified in

Technical Data

.

3

Repeat step

2

and note gauge readings with engine running at 2000 rev/min. If the pressure is high the oil cooler may be blocked, (see

Converter Out

Pressure/Oil Cooler Flow Rate

).

4

Stop engine and remove pressure gauge.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

66 — 7

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 7

Powershift Gearbox

Pressure and Flow Testing

Y

A

J

Z

T

U

L

S

X

9803/3280

M

F

B

W

V

C

Purchased from www.WorkshopManuals.co.uk

A396470

Issue 1

Section F

66 — 8

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 8

Powershift Gearbox

Pressure Testing — Clutches

Isolating a Suspect Clutch

By performing the tests in the first 3 gears in forward and reverse all the clutches in the gearbox will be engaged, ensuring any clutch leakage will be easy to identify. Draw a table as shown so that you can record the results.

Clutch Pressure Test Results — 6 Speed Powershift

Gear Clutches engaged

Forward bar lbf/in

2

Reverse bar lbf/in

2

1st X,Z W,Z

3

Start engine and run at 1000 rev/min, engage 1st gear forward. Record the pressure reading. Repeat the test for 2nd and 3rd gears forward and 1st, 2nd and 3rd gears revers. Record the pressure readings as shown in the example below:

Clutch Pressure Test Results — 6 Speed Powershift

Gear Clutches engaged

Forward bar lbf/in

2

Reverse bar lbf/in

2

1st X,Z 13.4 194 W,Z 13.4

194

2nd V,Z 13.6

197

2nd T,Z V,Z

T,Z 12.0 175

3rd U,Z 13.5 195 W,Y 13.5

195

3rd U,Z W,Y

Clutch Pressure Test Results — 4 Speed Powershift

Gear Clutches engaged

1st

2nd

3rd

Forward bar lbf/in

2

Reverse bar

T,Z

U,Z

T,Y

W,Z

V,Z

W,Y lbf/in

2

1

Stop engine, connect a 0-20 bar (0-300 lbf/in

2

) pressure gauge to test connector

A

(mainline pressure test point).

2

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.

Note:

When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational.

Alternatively, disconnect the switch at the park brake.

Readings should not vary between clutches by more than

0.7 bar (10 lbf/in

2

). In the example shown, we can see that pressure is low when 2nd gear forward is selected, indicating clutch leakage.

From the table we that the layshaft clutch

Z

is working normally (1st and 3rd gear forward and 1st and 2nd gears reverse all show normal operating pressure). We can assume that the forward low clutch

T

is leaking.

By carring out ‘Individual Clutch Leakage Tests’, (see next page) we can confirm that the forward low clutch

T

is leaking.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

66 — 9

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 9

Powershift Gearbox

Pressure and Flow Testing

Y

A

J

Z

T

U

L

R

S

X

M

9803/3280

F

B

W

V

C

Purchased from www.WorkshopManuals.co.uk

A396470

Issue 1

Section F

66 — 10

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

66 — 10

Powershift Gearbox

Pressure Testing — Clutches

Individual Clutch Leakage Test

When testing individual clutch pressures it is necessary to isolate the clutch being tested. So for instance, on a 6 speed gearbox, to check the

forward low clutch T

we must select

2nd gear forward — this would energise the

forward low

(

T

)

and layshaft

(

Z

) clutches. Because we only want to check the

forward low

(

T

) clutch pressure and not the

layshaft

(

Z

) clutch pressure, remove the electrical connector to the

6 speed

clutch solenoid

Zs

BEFORE selecting 2nd gear.

Use the table below to determine which solenoid electrical connectors should be removed when pressure testing individual clutches. Note that as the first 3 forward and reverse gears utilise all clutches, there is no need to select other gears when testing for leakage.

6 Speed Gearbox

Gear

Selected

Clutches Engaged (Solenoids Energised)

1st Forward 6 Speed & Layshaft — X,Z (Xs,Zs)

2nd Forward Forward Low & Layshaft — T,Z (Ts,Zs)

3rd Forward Forward High & Layshaft — U,Z (Us,sZ)

1st Reverse Reverse Low & Layshaft — W,Z (Ws,Zs)

2nd Reverse Reverse High & Layshaft — V,Z (Vs,Zs)

3rd Reverse Reverse Low & Mainshaft — W,Y (Ws,Ys)

4 Speed Gearbox

Gear

Selected

Clutches Engaged (Solenoids Energised)

1st Forward Forward Low & Layshaft — T,Z (Ts,Zs )

2nd Forward Forward High & Layshaft — U,Z (Us,Zs)

3rd Forward Forward Low & Mainshaf — T,Y (Ts,Ys)

1st Reverse Reverse Low & Layshaft — W,Z (Ws,Zs)

2nd Reverse Reverse High & Layshaft — V,Z (Vs,Zs)

3rd Reverse Reverse Low & Mainshaft — W,Y (Ws,Ys)

Ts

Us

Ws

Vs

Ss

Ys

Zs

Xs

In the following procedures the forward low clutch (

T

) is tested, therefore in step

2

a pressure gauge is connected to the forward low clutch test point.

When testing other suspect clutches connect a gauge to the relevant suspect clutch test point. Because the forward low clutch is suspect, a gear must be selected that will use the forward low clutch, in this instance 2nd gear forward.

Note:

When testing the 2/4WD clutch remove the feed pipe

R

and fit service tool. This pipe incorporates a test point.

Replace the original pipe when testing is complete.

1

Stop engine, connect a 0-20 bar (0-300 lbf/in

2

) pressure gauge to test connector

A

, (mainline pressure test point).

2

Connect a 0-20 bar (0-300 lbf/in 2 ) pressure gauge to test connector

T

(forward low ratio clutch test point).

3

Remove the layshaft clutch solenoid feed connector

Zs

, at the solenoid control valve. This ensures that only the forward low clutch

T

is energised when 2nd gear forward is selected.

4

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.

Note:

When fully engaged, the parking brake electrically disconnects the transmission drive; this prevents the machine from being driven with the parkbrake on. Therefore, so that we can complete the test, move the parkbrake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the parkbrake will not be fully operational.

Alternatively, disconnect the switch at the park brake.

5

Start engine and run at 1000 rev/min, select 2nd gear forward. Note the pressure readings on both gauges, which should not vary by more than 0.7 bar (10 lbf/in 2 ).

If the difference on the gauges is greater than 0.7 bar

(10 lbf/in 2 ) do the following:

a

Stop the engine and interchange the gauges.

b

Start the engine and run at 1000 rev/min, select

2nd gear forward. If the difference on the gauges is still greater than 0.7 bar (10 lbf/in

2

) dismantle the forward low clutch for servicing.

c

If after interchanging the gauges, the readings are different than at step

5

, have the gauges calibrated and repeat the testing procedure.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

67 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

67 — 1

Powershift Gearbox

Speed Sensor

Powershift machines fitted with an electronic control unit

(ShiftMaster ECU) or a speedometer have a speed sensor

D

fitted. The speed sensor detects the speed of rotation of the gearbox output shaft and relays this information to the ECU or speedometer as applicable.

The sensor detects the passing of the gear teeth on the output gear. When adjacent to the top of a gear tooth the sensor electrical output turns ON, when adjacent to a gap between the teeth the sensor output turns OFF. In this way the frequency of the electrical signal changes according to the speed of gear rotation and therefore machine road speed.

The ShiftMaster ECU uses the input from the speed sensor to determine gear shift points. Failure of the speed sensor or its wiring will enable an ECU ‘Limp Mode’, preventing the use of 4th, 5th, and 6th gears. See

Fault Finding —

Powershift Gearbox

.

Testing

The speed sensor can be tested in situ without removing it by means of service test harness 892/01096 .

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Lower the loader arms to the ground. Switch OFF the engine and remove the starter key.

2

Connect the test harness

E

as shown. Tie back and secure the wires clear of the driveshaft and other moving components, in a position where the light emitting diode (LED) can be seen while operating the machine.

3

Turn the engine ON and drive the machine forward approximately 2 m (6 ft), make sure it is clear in front.

Alternatively raise the wheels off the ground. If the sensor is operating correctly the LED will illuminate as the gear teeth pass the sensor, when the speed increases the LED will flash at a greater frequency until becoming continuously illuminated at higher speeds.

4

If the LED fails to illuminate carefully check the relevant wires and connectors for damage. Repair as required and re-test the sensor as described above. It should be noted that the speed sensor is normally a reliable component and a fault is more likely attributed to damaged wires or electrical connectors, see

Electrical

Connections — Powershift Gearbox — 6 Speed

.

E

D

B A

C

Key:

A

Ground

B

+V

C

Output

A405380

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

68 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

68 — 1

Powershift Gearbox — 6 Speed (ShiftMaster)

Electronic Control Unit

The PS766 6 speed gearbox is controlled by an Electronic

Control Unit (ShiftMaster ECU). The ECU is located behind the front console as shown at

A

.

The ECU is housed in a rugged case protected from ingress of dirt and moisture. Gearbox faults are more likely to be caused by faulty or damaged wiring, electrical components or hydraulic faults than by failure of the ShiftMaster ECU.

Fault Finding

When fault finding note the following:

Make sure you understand the normal operation characteristics of the 6 speed gearbox. Some characteristics may be interpreted as faults by some operators. See

Basic

Operation — ShiftMaster Operation Characteristics

.

The ShiftMaster ECU incorporates ‘Limp Modes’. These modes can operate in response to other gearbox faults.

Make sure you understand the characteristics of the ‘Limp

Modes’, see

Fault Finding — Powershift Gearbox

.

The simplest and best way to fault find the 6 speed gearbox electrical system, (including the ECU) is by using ShiftMaster

Diagnostics software and a laptop PC. See

Diagnostics

User Guide

. This diagnostics system enables the engineer to quickly identify faults with specific electrical circuits or devices. The devices electrical connections, locations and wire identifications are given in

Electrical Connections —

Powershift Gearbox — 6 Speed

. See also

Section C —

Harness Data

.

If the facilities to use the ShiftMaster Diagnostics software system are not available, the gearbox and ECU can still be checked using a conventional multimeter, see

Electrical

Connections — Powershift Gearbox — 6 Speed

. See also

Section C — Harness Data

.

Software Upgrades

From time to time a ShiftMaster ECU ‘Application Software’ upgrades may be made available by JCB Service. If necessary ‘Application Software’ can be loaded into the

ECU flash memory using a laptop PC and the

ShiftMaster

Flash Programmer

application. This application is part of the

JCB Service Master

package found on the JCB Service

Technical Information CD’s. The Flash Programmer application includes comprehensive help files.

Note that the ECU contains 2 sets of software, ‘Application

Software’ and ‘Setup Data’. The ‘Setup Data’ is specific to a machine variant and can not be changed or replaced.

Renewing The ECU

Before renewing the ECU note the following:

The ShiftMaster ECU is a

non serviceable part

. Any units returned under warranty found to have been tampered with will invalidate any claim.

ECU’s are configured at the factory for each machine variant and are not interchangeable between machines. Although the part numbers may be the same, the internal software may not be.

DO NOT interchange ECU’s between machines

.

Before renewing the ECU carry out all the relevant fault finding and diagnostics to

confirm ECU failure

. Units returned under warranty found not to be faulty will invalidate any claim.

A

9803/3280

A405370

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

69 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 1

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

1. Introduction

ShiftMaster Diagnostics

software is a PC based

Diagnostics Tool designed to be an easy to use fault finding tool for the Service Engineer using a laptop PC.

ShiftMaster

Diagnostics

employs the graphical strengths of the

Microsoft Windows operating environment to simplify electrical fault finding within the ShiftMaster ECU control system used on Powershift PS766 6 speed gearboxes.

ShiftMaster Diagnostics

is only intended for use with the

ShiftMaster ECU and does not support older versions of

Powershift Controllers used on the PS750 series gearboxes.

To utilise any supporting ShiftMaster Service Tools requires the use of the JCB Data Link Adaptor [or DLA] (717/ 20138) which is part of the standard JCB Electronic Service Tool

Kit, part number 892/01033.

2. Care & Safety

!

WARNING

Be sure to read and follow any on-screen instructions issued by ShiftMaster Diagnostics. Failure to follow correct procedure could result in death or injury.

S404180

S404170

This software is intended for use on IBM Compatible

Personal Computers

(PCs)

running

Windows 9x

or

Windows2000

operating systems but is not compatible with either earlier versions of

Windows 3.x

.

All distributed software can be found on Disk 3 (CD3 —

Adobe) of the JCB Technical Information Parts and Service

CD-ROM set from

Issue 19

onwards. This disk is also supplied as part of the Electronic Service Tool Kit. Copies of this CD-ROM can be purchased from JCB Service.

Alternatively, in due course software will become available for download over the internet via JCBs’ Techweb service.

Please refer to the available software for full installation instructions.

3. Installing ShiftMaster Diagnostics

The

ShiftMaster Diagnostics

tool is fully integrated within

JCB ServiceMaster.

For full instructions on how to install the

ShiftMaster

Diagnostics

software please refer to the documentation which accompanies JCB Service Master.

If you have successfully installed

ShiftMaster Diagnostics

but are experiencing difficulties with getting your PC to communicate with an ECU then there is a Troubleshooting

Guide built into the

ShiftMaster Diagnostics

Help menu.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

69 — 2

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 2

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

4. Starting ShiftMaster Diagnostics

This document assumes that JCB Service Master has already been installed.

Step 1

: Connect either the ‘Serial PC Cable’ (717/20138) or the ‘Parallel PC Cable’ (721/11071) between the DLA and a free port your laptop computer.

The ‘Parallel PC Cable’ has a 25-way D-type connector on both ends or the lead.

Step 2

: Connect the ‘Machine Cable’ between the DLA and the machines’ Diagnostic Connector. The ‘Machine Cable’ has a 15-way D-type connector on one end and a 9-way

CAN connector on the other. Plug the 15-way connector into the DLA and tighten the thumb-screws, then connect the 9way CAN connector into the machines’ Diagnostics

Connector

A

and twist the lock-ring to secure it.

S404200

S404190

The ‘Serial PC cable’ has a 9-way D-type connector on one end and a 25-Way D-type connector on the other.

S404190

Plug the 25-way male connector into the DLA and the other connector into a free port on your laptop PC, remembering to tighten any thumb-screws appropriately.

B

C

J

D

A

E

F

G

H

A

A405350

Step 3

: Turn ON the machine ignition and additionally start the engine if required (taking normal precautions).

Note

: Be sure to follow all the cautionary notes given earlier and those which accompany the software.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S404180

Issue 1

Section F

69 — 3

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 3

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

Step 4

: Start

JCB Service Master

. And go to the BHL section.

Connection Problems

:

ShiftMaster Diagnostics

will start and can be partly used even if there are connection problems.

In general, whenever there are problems communicating with the DLA there will be an error message displayed.

S404210

Step 5

: Start the diagnostics tool running by clicking on the

ShiftMaster Diagnostics

icon.

S404140

More specifically, if communications can not be established with the DLA then the ECU Setup Page will display

‘NO DLA

COMMS’

where the ECU Part Number should be.

S404220

Step 6

: The

ShiftMaster Diagnostics

tool will then open up displaying the main window as shown here.

S404150

If communications can not be established with the ECU then the ECU Setup Page will display

‘NO ECU COMMS’

where the ECU Part Number should be.

S404230

Step 7

: To start the

ShiftMaster Diagnostics

tool communicating with the ShiftMaster ECU either click on the

Start

button or select

Start Diagnostics

from the Options Menu. (See later sections for full details.)

S404160

Note:

The ECU must be powered for communications to work, i.e. the machine ignition must be ON (but the engine need not be running).

For further details on possible communication problems please consult the

Troubleshooting Guide

included in the

Help menu.

S404240

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

69 — 4

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 4

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

5. ShiftMaster Diagnostics: Overview

There are several key elements to the

ShiftMaster

Diagnostics

tool. These can be seen labelled below. Each element is explained in detail in later sections.

Menu Bar

Main Window

Start/Stop Buttons

Page Display Area

ECU Setup Page

Page List LED Status Key Status Bar ECU Status Page Dashboard Page

S404250

Navigating within ShiftMaster Diagnostics

Navigation is designed to be via a mouse. On Laptop PCs this may take the form of a small joystick or touch sensitive pad and some buttons, usually located near to the keyboard.

As with most Windows based programs, it is possible to navigate

ShiftMaster Diagnostics

using the keyboard by pressing certain combinations of keys.

Note

: This can be particularly useful for certain Laptop PCs where the mouse/joystick can be over-sensitive. Try out the following, it may come in useful one day.

There are two main methods of navigation described below; the key will cause the File option on the

Menu Bar to be highlighted. You can then use the arrow keys to navigate the menus.

· Notice that all the menu items on the Menu Bar have a letter that is underlined (e.g. the ‘F’ in

File

). Holding down the ALT key and pressing the required letter key will activate that option (i.e. either open the menu or execute a function). For example, if you wish to open the Preferences Dialogue this can be done by pressing

ALT + O

(to open the

Options

menu) then

ALT + P

(to execute the

Preferences

… option).

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

69 — 5

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 5

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

6. Menu Bar

File Menu

The File Menu contains and

Exit

option to close down the program.

S404260

On exiting the program communications with both ECU and

DLA are shut down.

Options Menu

Select either:

Start Diagnostics

to commence communications with the

ShiftMaster ECU.

or

· English (British)

· French (Standard)

· German (Standard)

· Spanish (Modern Sort)

Note

: The language option only effects text within the Main

Window (e.g. Page List, LED Status Key, etc…). At present language support is not offered for the text within the Page displays.

The Preferences Dialogue also offers the ability to change the background colour of the Page displays. Select the required background colour using the radio buttons.

S404300

Note:

When using a laptop PC it can often be difficult to see the screen in bright sunlight. Changing the background colour can help improve the contrast (especially with the different LED colours) and so make viewing the screen easier. Examples of the different colours are shown below;

S404270

Stop Diagnostics

to cease communications.

Clicking on the

Preferences

… option opens up the

Preference Dialogue.

S404310

S404320

S404280

From the Preferences Dialogue there is support for multiple languages. Use the drop-down menu and scroll bar to chose the required language. Languages presently on offer are:

Once your preferences have been selected either:

Click on to apply them or click on to leave them unchanged.

S404330

9803/3280

S404290

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

69 — 6

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 6

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

Window Menu

Like most other Windows based programs where there are multiple sub-windows or Pages used, there are usually options to organise how they are laid-out.

ShiftMaster

Diagnostics

is no different and offert the following options;

· Cascade

· Tile Horizontally

· Tile Vertically

Note

: Laptop PCs, particularly older ones, tend to have a low screen resolution. If this is the case then the Horizontal and Vertical tile options will probably be of little use and

Cascade will offer the best advantage.

Help Menu

To assist the Service Engineer,

ShiftMaster Diagnostics

is supplied with a set of documentary Guides. These Guides can be accessed directly from within the

ShiftMaster

Diagnostics

tool itself, via the Help menu.

Note

: All the Guides are provided in Adobe Acrobat PDF format. In order to read these guides the user must first have the Adobe Acrobat Reader installed on the PC. This software is supplied on the JCB CD-ROM where full installation instructions are provided.

At present these guides are as follows;

User Guide

: This file is provided to explain how all the functions of the

ShiftMaster Diagnostics

tool operate.

Fault Finding Guide

: Provided to help the user to understand how the PS760 gearbox electrical system operates. This Guide also offers advice on fault diagnosis along with example scenarios, hints and tips.

S404370

Selecting the

About

… option will bring up a window showing the JCB part number and the version number of the installed copy of

ShiftMaster Diagnostics

.

S404380

S404390

S404360

Troubleshooting Guide

: Sometimes users may experience problems with getting

ShiftMaster Diagnostics

to communicate properly with the ShiftMaster ECU. The

Trouble shooting Guide has been provided to explain possible causes of problems with communications.

7. Start/Stop Buttons

These offer the same function as the

Start Diagnostics

and

Stop Diagnostics

options within the Options Menu.

To start the

ShiftMaster Diagnostics

tool communicating with the ShiftMaster ECU simply click on the

Start Button

(big green LED) at the top of the Main Window.

Similarly, click on the

Stop Button

(big red LED) to cease communications.

S404240

9803/3280

S404400

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

69 — 7

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 7

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

8. Page List

In the top left corner of the main window is displayed a list of pages which can be displayed.

10. ECU Setup Page

This page displays crucial information about the ECU configuration.

S404410

Clicking in the box next to the required page with make that page appear in the main window display area. (A tick will also appear in the box to show it is being displayed.)

At any time the user may swap between displayed pages simply by clicking on the title of the required page in the page list.

S404420

9. Status Bar

There are 2 items of interest displayed on the

Status Bar

, which is located along the bottom of the

ShiftMaster

Diagnostics Main Window

.

Connected ECU

: The type of ECU connected to the

ShiftMaster Diagnostics

tool is indicated on the far left side of the Status bar.

S404430

CAN communications

: Two small LEDs indicate data being transmitted (red) and received (green) over the CAN communications link.

S404440

These LEDs can be seen to be flashing rapidly as data is transported. This can be another useful aid to determining the state of any established communications.

S404450

It is always useful to confirm that this is the correct configuration for the machine before commencing any fault finding.

The ECU Setup Page displays the following information;

ECU Part Number

This will display the part number of the connected

ShiftMaster ECU.

If there are communications errors present then this will contain either; a). ‘

NO DLA COMMS

‘ if there are problems communication with the DLA, or b). ‘

NO ECU COMMS

‘ if the DLA is working but the

ShiftMaster ECU is not responding.

Note

: If communications problems are suspected then please consult the accompanying

Troubleshooting Guide

for further information.

Hardware Version

This hardware version is a reference to the build level of the electronics. Future developments may mean that hardware upgrades are required. This may effect which software can be used.

Software Version

The software version refers to the issue level of the ECU operating software. Again, future developments may require software revisions.

ECU Setup Description

As well as its’ operating software, the ShiftMaster ECU also stores a group of

Setup Data

(or Settings). This Setup Data is used to tailor how a certain ECU part number functions.

The Setup Data is loaded during the manufacturing process and has been approved for use in the intended application.

Contained as part of the Setup Data is a Description. This

Description is what is displayed here. The Engineer can use this description to verify that the correct Setup Data is being used.

At present there is no service tool available to load new

Setup Data

.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

69 — 8

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 8

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

11. Dashboard

This offers a simple uncluttered display showing;

S404460

Requested Gear

This is the demand from the driver.

Selected Gear

This is the actual gear being selected by the ECU.

Note

: The driver

Request Gear

is not always the same as the Selected Gear, e.g. when the ECU blocks shifts when offering protection.

Transmission Speed

This is the current transmission output speed which is directly related to the road speed (through axle ratio and tyre size). The transmission speed sensor is located next to the output gear and detects the passing of the gear teeth. The sensor has a fixed installation, no adjustment is necessary.

The Transmission Speed value is a frequency reading and is displayed in Hertz (Hz), or teeth per second.

This signal is used by the ECU to determine gear-shifting and protection strategies.

12. ECU Status Page

This page gives a detailed picture of how the ECU is operating.

Information in this display is constantly updated in real-time.

(Some older PCs may experience a slight delay in updating this page, but usually only less than one second.)

The left hand side shows the inputs to the ECU, their status indicated by green LEDs.

The right hand side shows the outputs from the ECU, their status shown by red LEDs.

The exact colour of the LED indicates the status of that feature.

A key in the bottom left corner of the main window explains the colours.

S404480

The following is a brief explanation of each feature. For further information and examples of typical scenarios please refer to the accompanying Fault Finding Guide accessible via the Help menu.

Transmission Speed

This is exactly the same signal as explained in the previous section.

Gears

Inputs:

The items on the left show the signal lines connected to the gear selection lever. This lever if the left hand half of the control lever assembly mounted on the steering column.

Outputs

: The items on the right are the power signals going down to the transmission solenoid valves. The LEDs will indicate which solenoids are being energised. Error detection on the output electrics is continually running. If any output were to develop a fault (e.g. open circuit or short circuit) then the LED will turn yellow. Fix the fault and the

LED will revert back to red.

During certain gear-shifts the ShiftMaster ECU will perform electrical

Modulation

to improve gear-shift quality. The ECU does this by adding delays to off-going and/or on-coming clutches and so overlapping energised outputs. These delays are in the order of a few hundred milli-seconds but it is sometimes long enough to be observed on the status

LEDs. Thus, during certain shifts it is quite normal to observe more than 2 outputs ON at any one time.

9803/3280

S404470

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

69 — 9

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

69 — 9

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — User Guide

4WD

The machine driver has 2 inputs which are used to influence the state of the 4WD solenoid output. These features interact as follows;

Firstly there is a

Direct 4WD

input which is, in general, connected to the machine footbrake switch (which in turn controls the brake lights). Whenever this signal is present the

4WD Solenoid output

is energised.

The second input is

Indirect 4WD

which is usually derived from a command from a console mounted ‘4WD selector’ switch. (However, this switch arrangement may change between machines.) If the transmission speed is too high then the ECU will over-ride this signal and automatically disengage the 4WD.

Misc. Inputs

These inputs are derived from the remaining driver controls.

A brief summary follows but refer to the

Fault Finding Guide

for full details.

Handbrake Switch

: Signal derived from the Parkbrake switch. Used to hold the transmission in Neutral if the parkbrake is applied.

Dump Switch

(or Transmission Disconnect): Signal usually derived from a momentary switch fitted to a loader lever.

Temporarily selects Neutral when pressed (usually to divert engine power to hydraulics).

Throttle Switch

: Dedicated switch fitted to the machines’ accelerator pedal. Used to interact with the Automatic Mode of gear-shifting.

Pressure Switch

: Signal is derived from the transmission mounted Low Oil Pressure Switch.

Kickdown Switch

: Another momentary button (mounted on the cab floor) used to temporarily select the next lowest gear.

Misc. Outputs

These are the additional ECU outputs, generally used to control cab instrumentation like the low

Oil Pressure Lamp

and Driver

Indicator

(lamp and buzzer where fitted).

13. General Information

For all enquiries about the

ShiftMaster Diagnostics

tool please follow your normal channels of enquiry. This ensures that useful information can filter through to JCB Service personnel at all levels.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

70 — 1

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

70 — 1

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — Troubleshooting Guide

1.

Introduction

If you are experiencing difficulties with getting

ShiftMaster

Diagnostics

and your PC to communicate with a

ShiftMaster ECU

then please take a little time to read the following information which has been compiled to guide diagnosis of such problems.

To utilise any supporting ShiftMaster Service Tools requires the use of the

JCB Data Link Adaptor

(DLA) which is part of the standard J

CB Electronic Service Tool Kit

, part number

892/01033

.

This software is intended for use on IBM Compatible

Personal Computers

(PCs)

running

Windows 9x

or

Windows2000

operating systems but is not compatible with either earlier versions of

Windows 3.x

.

It is known that some laptop PCs can experience problems with serial communications.

In a few rare cases the PCs hardware does not allow the diagnostics software access to communications (COM) ports.

JCB Service are in the process of compiling a

‘recommended’ list of laptops which we know to work satisfactorily with JCB Software.

In the majority of cases conflicts are caused by either software already running on the PC, or by certain ‘driver’ files which hog the COM port(s).

Note:

a PC which has many users and uses is likely to contain some redundant software and drivers.

If you do not feel technically competent to adjust PC software & set-up, please enlist the help of someone suitably trained before proceding.

2.

Elementary Checks

Please make sure that the correct communications leads are being used and are not damaged in any way.

Non Communication with DLA

In general, whenever there are problems communicating with the DLA there will be an error message displayed.

S404140

More specifically, if communications can not be established with the DLA then the ECU Setup Page will display

‘NO DLA

COMMS’

where the ECU Part Number should be.

S404150

Non Communication with ECU

If communications can not be established with the ECU then the ECU Setup Page will display

‘NO ECU COMMS’

where the ECU Part Number should be.

S404160

Note:

The ECU must be powered for communications to work, i.e. the machine ignition must be ON (but the engine need not be running).

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

70 — 2

www.WorkshopManuals.co.uk

Transmission

Service Procedures

Section F

70 — 2

Powershift Gearbox — 6 speed

ShiftMaster Diagnostics — Troubleshooting Guide

3. DLA Drivers

The DLA has software ‘drivers’ (i.e. programs which handle communications) programmed into the unit. There are matching drivers that must also be resident on you PC.

The update of both these sets of drivers is handled by JCB

Service Master. Please refer to the applicable supporting literature.

5. IR Drivers

Many Laptop PCs have a built in InfraRed (IR) communications port. There is likely to be some resident software to control this port. If this type of port is present, but never used, then try disabling the driver;

System Properties > Device Manager > Ports > ….. (infrared)

4. PC Power Management

Some laptops’ Power Management software can disrupt the

COM ports.

This problem occurs with many other software applications and is not unique to JCB Service Master applications. The following advice is worth bearing in mind.

If the user experiences communications problems with a

ShiftMaster ECU

turn OFF the laptops’ power management software.

Problems may be;

(a) Complete failure to establish communications with an

ECU.

ECU and after a while the link fails).

(c) Intermittent failure (i.e. seems to disconnect and reconnect at random intervals).

Item (a) is probably the most common.

To turn OFF the laptops power management open

Windows

Control Panel

(Start > Settings > Control Panel). There will normally be an icon to run that particular laptops’ power management software. Turn OFF the power management, close the tool and then close the control panel.

These power management tools are specific to the laptop.

Some may require the PC to be re-booted before the changes take effect.

6. Modem Drivers

Check that only the correct modems are installed on the machine.

Experience has shown that multi-user PCs often contain many modems, perhaps installed for use other than in the office.

Disable any unused modems.

There has been no experience of correctly installed internal modems or PCMCIA cards (modem or network) causing significant problems.

7. Windows XP & Windows NT

Please note the ShiftMaster Diagnostics software is NOT designed to run on Windows NT. In addition JCB can not guarantee that this software will be fully functional with the latest versions of Windows (e.g. WindowsXP) although JCB are continually developing support for different operating systems.

8. Further Assistance

If a communication problem persists, then the following contacts may be able to provide further assistance; a). If applicable, try seeking assistance from your

Computer Systems Engineer/Technician.

b). The first port of call outside your company should be the laptop machine dealer or agent.

c). Your next enquiries should be with the laptop machine

OEM (Original Equipmemt Manufacturer). If the OEM is unable to assist they will make the relevant enquires on your behalf.

If you continue to have a communications problem, note the applicable laptop make and model. Contact JCB

Service so that further investigations can be made..

For all enquiries about the ShiftMaster Diagnostics tool please follow your normal channels of enquiry. This ensures that useful information can filter through to JCB Service personnel at all levels.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

75 — 1

www.WorkshopManuals.co.uk

Transmission

Propshafts

Section F

75 — 1

Propshafts

Removing and Replacing

When Removing

Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.

When Replacing

Upon reassembly, after lubricating sliding joints with JCB

MPL Grease, align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturer’s alignment markings.

Apply JCB Threadlocker and Sealer to threads of all flange bolts.

Retaining straps

C

stretch with use, therefore these straps must always be replaced with new ones.

The propshaft must have both ends exactly on the same plane as shown at

X

. The yokes must not be at right angles as at

Y

or at an intermediate angle as at

Z

.

Torque Settings

Item

A

B

Nm

75 — 85

118

kgf m

7.7 — 8.7

12

lbf ft

55 — 63

87

A

REAR

B

A396840

X

Y

Z

9803/3280

C

A

S232350

A

S189610

FRONT

Purchased from www.WorkshopManuals.co.uk

A

S157500

Issue 1

Section F

80 — 1

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

80 — 1

Removal and Replacement

K

C

-238.14

A

9803/3280

J

J

C

D

F

G

E

H

B

Purchased from www.WorkshopManuals.co.uk

B

A401290

Issue 1

Section F

80 — 2

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

80 — 2

Removal and Replacement (cont’d)

Note:

The following procedure can be applied to both AWS and 2WS machines. Dis-regard information not applicable to your machine type, for instance, 2 wheel steer machines will not have steering proximity switches fitted.

!

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.

GEN 1-1

Removal

!

WARNING

Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

GEN 3-2

1

Release screws

J

and remove the front grille.

2

Remove the cover

K

from the proximity switch and then remove the bracket and switch assembly.

3

Using tool 892/00822 remove bolts

A

to disconnect the drive shaft from the axle.

4

Disconnect the hydraulic pipes

B

from the steer rams, blank off all exposed connections.

5

Disconnect remote grease nipple hose

H

.

6

Loosen the road wheel retaining nuts

D

.

7

Make sure that the rear wheels are blocked, use the loader arms to raise the front end of the machine.

8

Prop the machine on each side as shown at

C

.

9

Remove the front road wheels.

10

Position a jack underneath the balance point (see Note) of the axle and support the axle weight.

Note:

Because the drivehead assembly is offset, the balance point of the axle is not the centre of the axle. Attach a

‘cradle’ to the jack that will partially embrace the axle.

11

Remove nut

E

and pivot pin retaining bolt

F

.

12

Remove pivot pin

G

seals, use puller (tool no.

993/68100) and remove the pivot pin

G

and axle shims.

13

Lower the jack so that the axle is clear of the mounting yoke and remove the axle.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

80 — 3

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

80 — 3

Removal and Replacement (cont’d)

Replacement

Replacement is the reverse of the removal sequence.

!

WARNING

If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

2-3-2-8

Y

Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

Apply JCB Lock & Seal to the threads of bolts

A

.

The front axle must be shimmed to give a maximum fore and aft movement of 0.5 mm (0.020 in).

Nylon shims must be fitted as follows:

AWS Machines a

Fit a 5.0 mm thick master shim (coloured blue) between the front of the axle and the yoke plate as shown at

X

.

b

Measure the fore and aft movement and subtract 0.5

mm to obtain the required shim thickness. Fit the correct thickness shim between the rear of the axle and the yoke plate as shown at

Y

.

2WS Machines a

Fit a 5.0 mm thick master shim (coloured blue) between the rear of the axle and the yoke plate as shown at

Y

.

b

Measure the fore and aft movement and subtract 0.5

mm to obtain the required shim thickness. Fit the correct thickness shim between the front of the axle and the yoke plate as shown at

X

.

Note 1:

DO NOT fit more than 2 shims (including the master shim).

Note 2:

To assist assembly, use the double sided tape ring supplied to retain the shims on the yoke plate.

If the setting of the steering proximity switch has been disturbed, then complete the front axle proximity switch setting procedure, see

Section H, Service Procedures

.

Torque Settings

Item

A

D

Nm

79

680 kgf m lbf ft

8 58

69 500

X

A258180

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

81 — 1

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 1

Hub and Driveshaft — Dismantling

The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the axle.

!

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.

GEN 1-1

1

Disconnect the steering track rod. Drain oil from the hub.

Note:

The illustration shows a typical axle.

2

Remove screws

A

.

3

Lever the planet gear carrier

B

off the bearing carrier.

Clean off all traces of sealant from the mating faces or remove ‘O’ ring as applicable.

B

A

S258220

4

Remove planet gears only if defective. Note that gears can only be removed as assemblies, which comprise the gear, the bearing and two ‘ L’ shaped circlips. To remove a planet gear, first remove the external circlip.

5

Pull off the planet gear.

6

The driveshaft thrust pad

C

is drilled and tapped M6 for removal purposes.

C

255920

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

81 — 2

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 2

Hub and Driveshaft — Dismantling (cont’d)

7

Remove circlip

D

to allow the sun gear to be slid off the drive shaft.

E

D

256010

8

To remove the ‘Verbus Ripp’ bolts

E

, it is necessary to remove the spacer

F

. Revolve the spacer with a suitable drift to align the holes in the spacer with the space between the bolts.

9

Using two dowels and two heel bars, remove the spacer using the method shown.

10

Remove the ‘ Verbus Ripp’ bolts using a special tool

(part number 892/00333). These bolts are very tight and care must be taken not to distort the bolt heads. Use as short an extension bar as possible.

F

255930

11

Using 2 high grad e M 14 b olt s as jac king sc rew s, remove the annulus carrier.

Note:

Fretting between the hub swivel and annulus carrier mating faces might be evident; this condition is normal, do not attempt to repair. If the hub swivel and annulus carrier are to be re-used, the carrier must be assembled in the same angular position it was removed; match mark the hub swivel and carrier before removing the carrier.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S258240

Issue 1

Section F

81 — 3

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 3

Hub and Driveshaft — Dismantling (cont’d)

12

Remove circlip

G

to separate the annulus ring from the annulus carrier.

G

S248910

13

Pull off the bearing carrier together with the outer bearing cone and its bearing cup. Withdraw the inner bearing cup from the inboard side of the carrier.

Note:

To prevent damaging the axle case inner seal, do not lever against the half shaft. Place a tube over the half shaft and lever against the tube, as shown at

X

.

S248920

9803/3280

A258390

Purchased from www.WorkshopManuals.co.uk

X

Issue 1

Section F

81 — 4

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 4

Hub and Driveshaft — Dismantling (cont’d)

14

Pull off the inner bearing — see Note at step 13.

15

Remove and discard the seal.

Note:

The inner bearing and oil seal may withdraw with the bearing carrier.

S258260

16

Remove and d isc ard t he c omb inat ion seal. When assembling the axle, a new combination seal must be used.

H

S248880

17

Mark position of top and bottom trunnions

H

and remove. Withdraw the hub carrier.

Note 1:

Trunnions may be removed easily by pumping grease through the grease nipple.

H

S248890

18

Use ad ap t o r 993/ 59500 w it h slid e ham m er t o o l

892/00224 and remove driveshaft seal and needle roller bearing from the hub carrier.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S161460

Issue 1

Section F

81 — 5

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 5

Hub and Driveshaft — Dismantling (cont’d)

19

Use a puller to remove the trunnion seal and bearing.

S258270

20

Withdraw drive shaft.

21

Prise out drive shaft inner oil seal

J

.

22

Remove circlip

K

23

Remove bearing using tool 892/00225.

J

K

255990

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

81 — 6

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 6

Hub and Driveshaft — Assembly

1

Tap drive shaft inner bearing into position and secure with circlip

K

.

2

Fit new oil seal

J.

Pack grease between lips of seal.

3

Fit drive shaft, taking care to locate inner end into splines of differential gears.

J

K

255990

4

Press new trunnion oil seal into position followed by the bearing. Grease bearing and oil seal before fitting to axle.

S258270

5

Fit driveshaft needle roller bearing to the hub carrier.

Pack the cavity between the oil seal lips with grease and then fit the seal.

S161460

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

81 — 7

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 7

Hub and Driveshaft — Assembly (cont’d)

6

Locate hub carrier and fit bottom trunnion. Apply JCB

Lock and Seal (part no. 4101/ 0202) to the bottom trunnion bolt threads, fit and tighten to 98Nm (72 lbf ft).

Fit top trunnion and leave top trunnion bolts finger tight.

S248890

7

Attach a spring balance to track rod swivel as shown and note the reading. Tighten the top trunnion bolts to eliminate end float but no bearing pre- load, ie no increase in spring balance reading.

8

Refit top trunnion. Apply JCB Threadlocker and Sealer to the top trunnion bolt threads, fit and tighten to 98 Nm

(72 lbf ft). Check spring balance reading which should be 4.5 kgf (10 lbf) more than the reading recorded at fig.

7.

9

Lightly oil the inner wheel bearing. Assemble the inner and outer bearing cups, and the inner bearing cone into the bearing carrier.

10

Fit a new combination oil seal. Do not lubricate before fitting. Drive the seal squarely into the carrier until the locating lip is flush as shown at

A

.

S248850

A

A267170

11

Fit the bearing carrier onto the axle arm. Lightly oil the outer wheel bearing race. Fit the bearing onto the axle arm. Rotate the bearing during fitting.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S248920

Issue 1

Section F

81 — 8

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 8

Hub and Driveshaft — Assembly (cont’d)

12

Assemble the annulus ring to the annulus carrier.

Secure with the circlip

G

.

G

S248910

13

Fit annulus assembly in the same angular position as removal (see

Note

,

Dismantling

, step 11) using new

‘Verbus Ripp’ bolts. Do not fully tighten bolts but allow the bearing carrier to rock slightly. Measure seal drag rolling force — see step 14.

Note:

Steps 13 to 16 describe measurement of rolling force.

To measure rolling torque (simplified process), a special tool is required. Refer to

Service Tools

.

14

To measure seal drag rolling force:

Refit the planet gear carrier — DO NOT FIT THE SUN

GEAR.

Use a spring balance and cord wrapped around the planet carrier flange as shown.

Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.

Remove planet gear carrier.

15

Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force — see step 16.

S248540

S248870

9803/3280

Purchased from www.WorkshopManuals.co.uk

S248540

Issue 1

Section F

81 — 9

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 9

Hub and Driveshaft — Assembly (cont’d)

16

To measure rolling force:

Refit the planet gear carrier — DO NOT FIT THE SUN

GEAR. Use a spring balance and cord wrapped around the planet gear carrier flange as shown. Pull the spring balance so that the hub rotates and record the reading.

To get the rolling force, subtract seal drag rolling force (see step 14) from reading obtained at this step, the result should be 64 to 117 N (14 to 26 lbf).

If the resulting figure is outside these limits check: the seal is fitted correctly; and/or renew bearings if necessary; and /or new fitted components.

Remove planet gear carrier.

17

Press the drive shaft thrust pad

C

(chamfered side lowermost) into the recess in the planet carrier.

18

Fit new planet gears in place of any that were removed.

(See step 4 in ‘Dismantling’). Secure with circlip.

Note:

Make sure that the SMALL radius on the gear bearing internal diameter is facing uppermost, that is at the circlip end of the planet pin.

S248870

C

255920

19

Fit spacer and slide the sun wheel onto the driveshaft and secure with circlip

D

. Apply a fillet of sealant

4102/0900 evenly around the bearing carrier as shown at

X

.

Note:

Some machines may have an ‘ O’ ring instead of sealant — where appropriate fit a new ‘O’ ring.

Note:

The sun gear must be fitted with the 1.5 mm (0.060 in) x 45° chamfer inboard.

X

D

S258230

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

81 — 10

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55, SD70

Section F

81 — 10

Hub and Driveshaft — Assembly (cont’d)

20

Fit the planet carrier onto the bearing carrier, ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and torque tighten screws

A

to

56Nm (41Ibf ft; 5.7kgf m) after applying JCB Lock and

Seal to the threads.

Note:

Do not strike the centre of the planet gear carrier when fitting as this may dislodge the driveshaft thrust pad fitted at step

17.

Re-fill hubs with the correct grade oil.

A

S258220

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

82 — 1

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Drive Head — Dismantling

Section F

82 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

ITL00670

Issue 1

Section F

82 — 2

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Section F

82 — 2

Drive Head — Dismantling (cont’d)

1

Drain the oil from the drive head. Remove the propshaft.

2

To remove the drive head it is necessary to withdraw both drive shafts from the axle.

3

Remove the drive head carrier screws

1

. Mark the installation position of drive head carrier

2

relative to the axle housing.

4

Remove the drive head carrier from the axle housing.

5

Pull out the roll pins

3

and remove the castellated nuts

4

. Remove the outer races of bearings

5

and

6

from the drive head carrier bores.

6

Remove inner bearing races of

5

and

6

.

7

Remove differential assembly

8

from carrier.

8

Loosen the differential case half bolts

7

and pull the case halves

8A

and

8B

apart. Remove the axle bevel gears

9

, the differential bevel gears

10

, trunnion pin

11

and thrust washers

12

from the case halves.

9

Remove the thrust washers

13

from both case halves.

10

Pull off the bearing

6

from case half

8A

.

11

Remove the Verbus Ripp bolts

14

and separate the crownwheel

15

from the case half

8A

.

12

Remove pinion nut

16

. Use Service Tool 892/00812 to prevent drive yoke

18

from rotating.

13

Mark the position of the drive yoke on the splined shaft.

Remove the drive yoke.

14

Drive pinion shaft

20

out of drive head carrier

2

.

15

Prise shaft seal

19

out of the bore.

16

Remove taper roller bearing

21

and tap out the outer bearing race.

17

Tap out the outer race of bearing

22

from the opposite bearing housing and remove the drive pinion shim(s)

23

.

18

Remove spacer

24

from drive pinion

20

. Prise taper roller bearing

22

to raise it sufficiently to insert bearing pullers. Pull the bearing from the pinion shaft.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

82 — 3

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Section F

82 — 3

Drive Head — Assembly (cont’d)

9803/3280

Purchased from www.WorkshopManuals.co.uk

ITL00670

Issue 1

Section F

82 — 4

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Drive Head — Assembly

The outline procedure below refers also to the following aspects of the drivehead assembly, which are covered separately in detail as sub topics later in this section:

Pinion Depth Setting

Collapsible Spacer Assembly

Crown Wheel and Pinion Meshing

Note:

Both the crownwheel

15

and pinion

20

and the bevel gears

9

and

10

are matched and should be renewed as sets if any of their components are damaged or excessively worn. The two differential housing halves

8A

and

8B

are also matched. Do not use unmatched halves.

Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set.

1

Determine the correct thickness required for the shims

23

, refer to

Pinion Depth Setting

.

2

Fit shims

23

behind new bearing cup

22

.

3

Fit new pinion head bearing cone

22

onto pinion

20

.

Section F

82 — 4

6

Fit special bracket

D

to the drive-head housing using two M10 x 30 nuts and bolts. Fit special tool support pillar

E

to bracket

D

so that the fork end engages in adapter

C

. Ensure that fork

E

is centrally located on adapter

C

. If necessary, re-align bracket

D

to suit.

D

E

C

B

4

Install pinion and bearings into the drive head casing.

Install largest available solid spacer

24

e.g (14.20 mm) and fit pinion tail bearing

21

(lightly oiled). Do not fit the oil seal

19

at this stage.

348030

7

Fit dial test indicator (DTI)

F

. Ensure that the DTI is mounted on the drive head and not on bracket

D

.

Note

: It should be noted that the axle is assembled using a solid spacer. However, in the absence of the special tools required or the correct size solid spacer

24

it is acceptable to fit a collapsible spacer, refer to

Collapsible Spacer

Assembly

.

8

Set torque wrench

G

to 35 Nm (25.8 lbf ft) and measure the end float while rotating the shaft.

G

5

Fit special tool sleeve

B

and special pinion shaft adapter

C

. Tighten adapter

C

to approximately 50 Nm, making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing. If the pinion is not free to rotate or there is no end float at this stage check the bearing is fitted correctly. Also check the correct size spacer has been fitted.

F

348040

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

82 — 5

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Section F

82 — 5

Drive Head — Assembly (cont’d)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

82 — 6

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Drive Head — Assembly (cont’d)

Section F

82 — 6

9

To select the right size spacer

24

, subtract the end float

11

obtained at step 7 from the solid spacer size (14.20

mm). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted from the solid spacer setting kit. If there is no spacer of this size, fit the next nearest size spacer, refer to

Service Tools — Axles

.

Example

Temporary spacer size

Subtract end-float

Total

Subtract tolerance & preload

Fit sleeve assembled correctly.

Remove adapter yoke

18

B.

Tighten adapter

C

and sleeve and NEW stake nut

C

16

.

0.25

13.95

0.04

Result 13.91

(No spacer available this size, use next nearest size spacer i.e 13.900)

10

Remove sleeve

B

and temporary spacer. fit correct size spacer from solid spacer setting kit, refer to

Service

Tools — Axles

. During removal take care to avoid damaging the outer bearing.

14.20

to no more than 50 Nm to protect against bearing damage while spacer selection is verified making sure the pinion is free to rotate. Check there is no end float and pinion is free to turn smoothly by hand. Remove adapter

16.

Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly.

B

C

and fit nut

Note:

If the pinion is not free to rotate check the correct size spacer has been fitted.

12

13

14

If rolling torque measured at step 10 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is

. Fit new oil seal

19

grease between seal lips before fitting. Fit coupling

Progressively torque tighten stake nut

16

, occasionally rotating coupling yoke, up to 250 Nm. Providing the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note:

The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm.

,

16

Assemble the trunnion pin

11

, bevel gears

9

and

10

and their thrust washers

12

and

13

into differential half case

8A

.

17

Position differential half case

8B

onto half case

8A

, aligning the match-mark letters. Apply JCB

Threadlocker and Sealer to the threads of bolts

7

, then fit and torque tighten to 46 Nm (34 lbf ft, 4.7 kgf m).

Check the gears for free rotation.

18

Fit crownwheel

15

using new Verbus Ripp bolts

14

tightened to 94 Nm (69 lbf ft, 9.59 kgf m).

19

Locate crownwheel assembly (without bearings) into housing.

20

Drive bearing cones

5

and

6

onto differential case spigots. Lightly oil the bearings then fit their bearing cups and castellated nuts

4

into drive head carrier

2

.

Do not fit the roll pins

3

at this stage.

21

Adjust castellated nuts

4

to give an increase in input pinion rolling torque of between 1.36 — 2.5 Nm (12 — 22 lbf in) more than that recorded in Step 13.

22

Measure the backlash between crownwheel

15

and pinion

20

, which should be 0.17 — 0.28 mm (0.006 —

0.010 in). Adjust castellated nuts

4

by equal amounts when altering backlash. When backlash and preload are both correct, fit roll pins

3

.

23

Check tooth marking to verify crownwheel and pinion are set correctly, refer to

Crownwheel and Pinion

Meshing

.

24

Apply JCB Multigasket to the mating faces of drive head carrier

2

and the axle casing. Fit the drive head carrier to the axle casing with the crownwheel towards the short drive shaft. Fit securing bolts

1

and tighten to

98 Nm (72 lbf ft, 10 kgf m).

25

Reassemble both driveshafts and hub assemblies, refer to

Axle Hub and Driveshaft — Dismantling and

Assembly

.

26

Re-fill the hubs and differential with the correct grade of oil, refer to Section 3

Lubricants and Capacities

.

27

Refit the propshaft, refer to

Propshafts — Removing and Replacing

.

15

Finally stake the nut

16

into the slot.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

82 — 7

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Section F

82 — 7

Pinion Depth Setting

1

Place new pinion head inner bearing assembly on a flat surface and position service tool 892/00174 over the bearing. Measure gap

A

(e.g. 0.20 mm) and add this to the cup depth stamped on the tool (e.g. 30.01 mm) to obtain the bearing depth.

A

2

From the face of the pinion, obtain the etched deviation figure

B

(e.g. + 2) which is in units of 0.01 mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth.

A184400

3

Obtain the deviation figure

C

(e.g. — 1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

4

Subtract the total of the above figures from the standard value of 31.19 mm. The result will be the thickness of shims required behind the pinion head bearing cup.

Example

(all dimensions in millimetres)

Cup depth

Gap

A

Bearing depth

Pinion deviation

B

(+ 2)

30.01

+0.20

30.21

+0.02

Housing deviation

C

(- 1) +0.01

Total 30.24

Standard value

Less Total above

Shim Thickness

31.19

30.24

0.95

B

S256110

Note:

In the event that the setting data stamp has been ommited from the drivehead casing, adopt the following setting procedure:

Revise the shim pack size by the difference in setting height marked on the old and new crownwheel pinion sets.

C

S256120

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

82 — 8

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD55

Section F

82 — 8

Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion.

The marking will then be transferred to the crown wheel teeth.

Correct tooth marking.

A386940

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

A386950

Pinion too far out of mesh.

Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A386960

Issue 1

Section F

83 — 1

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

S161871

Issue 1

Section F

83 — 2

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 2

Drivehead, SD70 — Dismantling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

1

Drain the oil from the axle centre casing. Remove the propshaft from the gearbox to the front axle.

2

Remove both hub assemblies complete with driveshafts (see

Hub and Driveshaft Dismantling

).

3

Mark the installation position of the drive head carrier, item

2

.

4

Remove the drive head carrier retaining bolts, item

1

, and remove the drive head carrier

2

from the axle casing.

5

Clean the drive head carrier and axle casing mating faces.

6

Pull out tension pins

3

and

4

, and remove castellated nuts

5

and

6

.

7

Remove bearing outer races

7

and

8

.

8

Drive off the taper roller bearing cone

9

from the crownwheel differential case half.

9

Remove the differential assembly

10

from the carrier.

10

Remove the differential assembly retaining bolts

11

and separate case halves

12

and

13.

11

Remove the differential side gears and thrust washers

14

and

15

respectively (2 off each).

12

Remove planet gears and thrust washers

16

and

17

respectively (4 off each) from trunnion pins

B

.

13

Pull off taper roller bearing cone

18

from differential case half

12.

14

Remove ‘ verbus ripp’ bolts

19

and separate the crownwheel

20

from the differential case half

13.

15

Mark the position of the drive yoke on the splined shaft.

Use service tool 892/00812 to prevent drive yoke

23

from rotating and remove pinion nut

22

. Remove the drive yoke.

16

Press the pinion

24

from the drive head carrier

2

.

17

Withdraw the pinion oil seal

25

and taper roller bearing cone

26

. If necessary, remove bearing outer race

27.

18

If necessary, drive out the pinion bearing outer race

28

and shim(s)

29

from inner side of the drive head carrier.

19

Remove the spacer

30

and taper roller bearing cone

31

from pinion

24.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

83 — 3

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 3

9803/3280

Purchased from www.WorkshopManuals.co.uk

S161871

Issue 1

Section F

83 — 4

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 4

Drive Head — Assembly

The outline procedure below refers also to the following aspects of the drivehead assembly, which are covered separately in detail as sub topics later in this section:

Pinion Depth Setting

Collapsible Spacer Assembly

Crown Wheel and Pinion Meshing

Note:

Both the crownwheel

20

and pinion

24

and the bevel gears

14

and

16

are matched and should be renewed as sets if any of their components are damaged or excessively worn. The two differential housing halves

12

and

13

are also matched. Do not use unmatched halves.

Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set.

1

Determine the correct thickness required for the shims

29

, refer to

Pinion Depth Setting

.

2

Fit shims

29

behind new bearing cup

28

.

3

Fit new pinion head bearing cone

28

onto pinion

24

.

4

Install pinion and bearings into the drive head casing.

Install largest available solid spacer

30

e.g (14.20 mm) and fit pinion tail bearing

26

(lightly oiled). Do not fit the oil seal

25

at this stage.

6

Fit special bracket

D

to the drive-head housing using two M10 x 30 nuts and bolts. Fit special tool support pillar

E

to bracket

D

so that the fork end engages in adapter

C

. Ensure that fork

E

is centrally located on adapter

C

. If necessary, re-align bracket

D

to suit.

D

E

C

B

348030

7

Fit dial test indicator (DTI)

F

. Ensure that the DTI is mounted on the drive head and not on bracket

D

.

Note

: It should be noted that the axle is assembled using a solid spacer. However, in the absence of the special tools required or the correct size solid spacer

30

it is acceptable to fit a collapsible spacer, refer to

Collapsible Spacer

Assembly

.

8

Set torque wrench

G

to 35 Nm (25.8 lbf ft) and measure the end float while rotating the shaft.

G

5

Fit special tool sleeve

B

and special pinion shaft adapter

C

. Tighten adapter

C

to approximately 50 Nm, making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing. If the pinion is not free to rotate or there is no end float at this stage check the bearing is fitted correctly. Also check the correct size spacer has been fitted.

F

348040

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

83 — 5

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 5

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

83 — 6

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 6

Drive Head — Assembly (cont’d)

9

To select the right size spacer

30

, subtract the end float obtained at step 7 from the solid spacer size (14.20

mm). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of

12

spacer to be fitted from the solid spacer setting kit. If there is no spacer of this size, fit the next nearest size spacer, refer to

Service Tools — Axles

.

Example

Temporary spacer size

Subtract end-float

Total

Subtract tolerance & preload

Result

If rolling torque measured at step 10 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly.

13

Remove adapter

C

and sleeve

B

. Fit new oil seal

25

, grease between seal lips before fitting. Fit coupling yoke

23

and NEW stake nut

22

.

14.20

0.25

13.95

0.04

13.91

(No spacer available this size, use next nearest size spacer i.e 13.900)

10

Remove sleeve

B

and temporary spacer. fit correct size spacer from solid spacer setting kit, refer to

Service

Tools — Axles

. During removal take care to avoid damaging the outer bearing.

11

14

Fit sleeve

B.

Tighten adapter

C

has been assembled correctly.

to no more than 50 Nm to protect against bearing damage while spacer selection is verified making sure the pinion is free to rotate. Check there is no end float and pinion is free to turn smoothly by hand. Remove adapter

C

and fit nut

16.

Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft

Note:

If the pinion is not free to rotate check the correct size spacer has been fitted.

Progressively torque tighten stake nut

22

, occasionally rotating coupling yoke, up to 250 Nm. Providing the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note:

The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm.

16

Assemble the trunnion pin

B

, bevel gears

14

and

16

and their thrust washers

15

and

17

into differential half case

13

.

17

Position differential half case

12

onto half case

13

, aligning the match-mark letters. Apply JCB

Threadlocker and Sealer to the threads of bolts

7

, then fit and torque tighten to 56 Nm (42 lbf ft, 6 kgf m).

Check the gears for free rotation.

18

Fit crownwheel

20

using new Verbus Ripp bolts

19

tightened to 166 Nm (122 lbf ft, 16.9 kgf m).

Note:

Verbus Ripp bolts must not be reused.

19

Insall the differential assembly

10

onto the drive head carrier

2

.

20

Press taper roller bearing cone

9

onto the spigot of case half

13

.

21

Fit bearing outer races

7

and

8

, castellated nuts

5

and

6

to the drive head carrier

2

.

22

Adjust castellated nuts

5

and

6

to give an increase in input pinion rolling torque of between 1.36 — 2.5 Nm (12

— 22 lbf in) more than that recorded in Step 11.

23

Measure the backlash between crownwheel

20

and pinion

24

, which should be 0.17 — 0.28 mm (0.006 —

0.010 in). Adjust castellated nuts

5

and

6

by equal amounts when altering backlash. When backlash and preload are both correct, fit roll pins

3

and

4

.

24

Check tooth marking to verify crownwheel and pinion are set correctly, refer to

Crownwheel and Pinion

Meshing

.

25

Apply JCB Multigasket to the mating faces of drive head carrier

2

and the axle casing. Fit the drive head carrier to the axle casing with the crownwheel towards the short drive shaft. Fit securing bolts

1

and tighten to

166 Nm (122 lbf ft, 16.9 kgf m).

26

Reassemble both driveshafts and hub assemblies, refer to

Axle Hub and Driveshaft — Dismantling and

Assembly

.

27

Re-fill the hubs and differential with the correct grade of oil, refer to Section 3

Lubricants and Capacities

.

28

Refit the propshaft, refer to

Propshafts — Removing and Replacing

.

15

Finally stake the nut

22

into the slot.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

83 — 7

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Section F

83 — 7

Pinion Depth Setting

1

Place new pinion head inner bearing assembly on a flat surface and position service tool 892/00174 over the bearing. Measure gap

A

(e.g. 0.20 mm) and add this to the cup depth stamped on the tool (e.g. 30.01 mm) to obtain the bearing depth.

A

2

From the face of the pinion, obtain the etched deviation figure

B

(e.g. + 2) which is in units of 0.01 mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth.

A184400

3

Obtain the deviation figure

C

(e.g. — 1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

4

Subtract the total of the above figures from the standard value of 31.19 mm. The result will be the thickness of shims required behind the pinion head bearing cup.

Example

(all dimensions in millimetres)

Cup depth

Gap

A

Bearing depth

Pinion deviation

B

(+ 2)

30.01

+0.20

30.21

+0.02

Housing deviation

C

(- 1) +0.01

Total 30.24

Standard value

Less Total above

Shim Thickness

31.19

30.24

0.95

B

S256110

Note:

In the event that the setting data stamp has been ommited from the drivehead casing, adopt the following setting procedure:

Revise the shim pack size by the difference in setting height marked on the old and new crownwheel pinion sets.

C

S256120

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

83 — 8

www.WorkshopManuals.co.uk

Transmission

Front Axle — SD70

Crownwheel and Pinion Meshing

Section F

83 — 8

Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion.

The marking will then be transferred to the crown wheel teeth.

Correct tooth marking.

A386940

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

A386950

Pinion too far out of mesh.

Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A386960

Issue 1

Section F

85 — 1

www.WorkshopManuals.co.uk

Transmission

Front Axle

Section F

85 — 1

Removal and Replacement

(2 Wheel Drive Machines)

The removal and replacement procedures for the 2 wheel drive axle (beam type) is the same as described on pages

F/80-1 and F/80-2. Dis-regard any information which is not pertinent to the 2 wheel drive axle.

Please note when using a ‘cradle’ to remove the axle from the machine, the balance point (see step 10, page F/80-2), of the axle on 2 wheel drive machines will be the centre of the axle, NOT offset as described on page F/80-2.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

86 — 1

www.WorkshopManuals.co.uk

Transmission

Front Axle

Section F

86 — 1

Dismantling and Assembly

(2 Wheel Drive Machines)

When Dismantling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

A suitable press will be required to remove and replace stub axle

22

.

When Assembling

Fit bushes

18

and

20

with open ends of grease grooves facing the axle beam.

Add shims

16

as required to give zero to 0.1mm (0.004in) clearance between axle beam and bearing

15

.

Apply JCB Lock and Seal to threads of bolt

9

.

Pack JCB Special MPL Grease into hubs

5

and between lips of seals

7

.

Bed in bearings

6

and

8

by rotating hub in each direction whilst tightening nut

3

. When correct torque setting has been achieved, back off one flat and fit split pin

2.

Torque Settings

Item

3

9

Nm

40†

30

kgf m lbf ft

4.0† 30†

3.0

21

† Back off one flat before fitting split pin.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S258280

Issue 1

Section F

90 — 1

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70, SD80

Section F

90 — 1

Removal and Replacement

D

D

-238.14

C

H

B

H

9803/3280

F

J

E

L

M

A

K

G

Purchased from www.WorkshopManuals.co.uk

A401300

Issue 1

Section F

90 — 2

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70, SD80

Section F

90 — 2

Removal and Replacement (cont’d)

!

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.

GEN 1-1

Removal

!

WARNING

When the propshaft is disconnected the parking brake will no longer function. The machine must be securely chocked to prevent any machine movement before disconnecting the propshaft.

TRAN 1-3

Removing

1

Release the parking brake. Loosen the parking brake cable bulkhead nuts at the bracket

L

. Disconnect the cable from the calliper

M

. Tie the cable up, out of harms way.

Replacement

Replacement is the reverse of the removal sequence.

!

WARNING

If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.

2-3-2-8

Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

!

WARNING

Bleed the brake system before driving the machine.

BRAK 1-6

2

Remove bolts

A

to disconnect the drive shaft from the axle.

3

Disconnect the brake pipes from the brake piston housings, shown at

H

. Remove tee piece

B

retaining bolt and remove the tee piece. Blank off exposed connections.

4 SD 80 Steer axles only;

Remove the cover

C

from the proximity switch and then remove the bracket and switch assembly.

5 SD 80 Steer axles only;

Label and then disconnect hydraulic pipes

D

from the steer rams, blank off all exposed connections.

6

Loosen the road wheel retaining nuts

E

.

7

Make sure that the front wheels are blocked, use the stabiliser legs to raise the rear end of the machine with the wheels and tyres clear of the ground.

8

Prop the machine on each side as shown at

F

.

9

Remove the rear road wheels.

10

Position a jack underneath the balance point (centre) of the axle and support the axle weight.

Note:

Attach a ‘cradle’ to the jack that will partially embrace the axle.

11

Remove nuts

G

, bolts

J

and washers

K

.

Bleed the brake system as described in

Section G, Service

Procedures

.

Check and adjust the operation of the parking brake as described in

Section G, Service Procedures

.

Apply JCB Threadlocker and Sealer to the threads of bolts

A

.

SD 80 Steer axles only;

If the setting of the steering proximity switch has been disturbed, then complete the rear axle proximity switch setting procedure, as described in

Section H, Service Procedures

.

Torque Settings

Item

A

E

G

Nm

79

680

607 kgf m lbf ft

8 58

69 500

62 448

12

Lower the jack and remove the axle.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

91 — 1

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70, SD80

Section F

91 — 1

8

7

9

16

15

2

6

5

11

13

14

12

3

10

17

B

A

2

3A

4

1

378120

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

91 — 2

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70, SD80

Section F

91 — 2

Brakes

(with controlled back off)

Axles are fitted with brake controlled back off to maintain a constant clearance of 0.6mm (0.02in) within the brake pack.

It is important that only one side at a time is dismantled to p revent d am ag e t o t he b earing s and p reserve t he crownwheel and pinion backlash setting.

!

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.

GEN 1-1

Dismantling

1

It is recommended that the axle be removed from the machine when dismantling the rear axle brakes.

2

Remove bolts

1

. Use a heavy duty socket to unscrew them.

3

Jack the axle arm off the drive head, using the drive head securing bolts. Remove all traces of gasketing from the mating faces.

4

There are two counterplates

2

, one at each end of the brake pack, which are not secured to the plate carrier

3

.

If the plates are to be re-used, note their positions and which way round they are then withdraw the brake pack.

5

Remove the circlip

4

. If the brake pack is to be re-used, note the positions of the plates before removing them.

6

Wear limit of friction plates is to the depth of the cross hatching

A

. Check all plates for flatness and damage.

(Some scoring of the counterplates is normal.) Renew the brake pack complete if worn or damaged. Do not renew individual plates.

7

Remove the three reaction pins

5

. Inspect for damage.

Note

: If new brake and friction plates are being fitted new brake back off pins and tension bushes must also be fitted.

Failure to do so could result in the brake being permanently on.

8

B ef o re rem o ving t he b rak e ho using and p ist o n assembly support the differential with a drive shaft or other suitable support, as shown at

6

.

9

Match mark the brake piston housing

7

and the drive head. Undo four capscrews

9

and remove the brake housing and piston assembly.

Note

: Do not disturb nut

10

otherwise the bearing pre load will have to be reset.

11

Remove circlips

11

, remove back off pins

12

, tension bushes

13

and springs

14

.

12

Remove brake piston

15

from brake housing

7

.

13

Remove and discard seals

16

and

17

. Inspect the housing bore for damage and scoring. Nicks or cuts in the seals may be responsible for loss of brake fluid.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

91 — 3

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70, SD80

Section F

91 — 3

8

7

9

16

15

2

6

5

11

13

14

12

3

10

17

B

A

2

3A

4

1

378120

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

91 — 4

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70, SD80

Section F

91 — 4

Brakes (with controlled back off) continued

Assembly

1

Clean all sealant from the mating faces of the drive head and the brake piston housing.

2

Fit new seals

17

and

16

. Make sure they seat squarely in their grooves.

3

Carefully press the piston

15

all the way into its housing

7

. Make sure the brake back off holes in the piston and housing align.

4

Apply JCB Threadlocker and Sealer to threads of back off pins

12

. Screw the back off pins

12

into the brake piston and fit the springs

14

over the back off pins.

5

Place the tension bush

13

over the back off pin

12

.

Using a suitable tool (steel tube) drive the tension bush onto the back off pin using a soft face hammer until the circlip

11

can just be fitted.

6

Apply JCB High Strength Gasketing to the drive head mating face, then fit the brake piston housing assembly.

Ensure that the match marks made during dismantling are aligned.

7

Fit capscrews

9

and torque tighten to 56 Nm (42 lbf ft,

5.7 kgf m).

8

Remove the differential support.

9

Assemble the friction plates and counterplates

2

onto the brake carrier

3

. If the original brake pack is being reused, return the plates to their original positions, see

‘Dismantling’. Soak new friction plates in JCB Special

Gear Oil before assembly. Fit circlip

4

.

On assembly of the brake packs, the oil flow holes

B

must be aligned with each other when being fitted to the brake plate carrier.

Note

: Item

3A

is fitted to non steer axles.

Note

: The illustration is typical only, refer to parts book or

General Bulletin 061 (G20/N.Am) for exact number of friction and counter plates.

10

Locate the three reaction pins

5

into their grooves, securing them with grease. Push the pins fully into their location holes in the housing.

11

Install one counterplate

2

into the housing, then the brake pack, then the other counterplate. Return re-used counterplates to their original positions. Push the brake pack fully home.

12

Apply JCB High Strength Gasketing to the mating face of the drive head, and JCB Threadlocker and Sealer to the threads of bolts

1

. Locate the axle arm onto the drivehead, with the embossed word ‘TOP’ on the axle arm uppermost.

13

Fit bolts

1

and torque tighten.

Note

: Check the grade of bolts fitted. Grade 8.8 should be tightened to 244 Nm (178lbf ft, 24.9 kgf m), grade 12.9

should be tightened to 400 Nm (295 lbf ft, 40.8 kgf m).

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

92 — 1

www.WorkshopManuals.co.uk

Transmission

Rear Axle — SD80

Section F

92 — 1

14

13

5

4

11

12

2

7

10

8

6

20

19

3

18

21

23

22

25

24

26

16

15

2

5

1

17

A313631

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

92 — 2

www.WorkshopManuals.co.uk

Transmission

Rear Axle — SD80

Section F

92 — 2

Hub — Dismantling

!

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.

GEN 1-1

1

Disconnect power track rod. Drain oil from hub.

2

Remove screws

1

.

3

Lever off the planet gear carrier

2

at the levering points.

Remove and discard the ‘O’ ring

3

.

4

Remove planet gears

4

only if defective. Note that gears can only be removed as assemblies, which comprise the gear, the bearing and two ‘ L’ shaped circlips. To remove a planet gear, first remove the external circlip

5

.

5

Pull off the planet gear assembly

4

.

6

The driveshaft thrust pad

6

is drilled and tapped M6 for removal purposes.

7

Remove circlip

7

to allow the sun gear

8

to be slid off the drive shaft.

8

Remove Verbus Rip bolts

10

. These bolts are very tight and care must be taken not to distort the bolt heads.

Use as short an extension bar as possible with a six sided socket. Discard the bolts after removal.

Note

: Fretting between the hub swivel and annulus carrier mating faces might be evident; this condition is normal, do not attempt to repair.

If the hub swivel and annulus carrier are to be renewed they must be renewed as a pair, not individually

9

Remove retaining plate

11

.

10

Mark the relationship between the annulus carrier, annulus ring and hub swivel, remove the annulus carrier

12

with annulus ring

13

.

11

Remove circlip

14

to separate the annulus ring

13

from the annulus carrier

12

.

12

Pull off the bearing carrier

15

together with the outer bearing

16

.

13

Pull off the inner bearing

17

.

14

Remove and discard combination oil seal

18

.

15

Mark the position of top and bottom trunnions

19

, undo bolts

20

and remove trunnions

19

. Withdraw the hub carrier

21

.

Note

: Trunnions may be removed easily by pumping grease through the grease nipple.

16

Using a puller, remove the trunnion seal

22

and bearing

23

.

17

Remove seal

24

and needle roller bearing

25

from hub carrier

21

.

Note

: Seal and needle roller bearing may be left on drive shaft. Production axles may be fitted with foam ‘masking rings’. These are used to protect the shaft from paint during axle spraying. The rings can be removed and discarded.

18

Withdraw drive shaft

26

.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

92 — 3

www.WorkshopManuals.co.uk

Transmission

Rear Axle — SD80

Section F

92 — 3

14

13

5

4

11

12

2

7

10

8

6

20

19

3

18

21

23

22

25

24

26

16

15

2

5

1

17

A313631

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

92 — 4

www.WorkshopManuals.co.uk

Transmission

Rear Axle — SD80

Section F

92 — 4

Hub-Assembly

1

Fit drive shaft

26

inner end into splines of differential gears.

2

Fit needle roller bearing

25

and seal

24

into hub carrier

21

. Pack grease between the lips of seal

24

.

Note

: Do not forc e fit b earing

25

and make sure t he manufacturer’s mark is facing out.

3

Locate hub swivel, aligning relationship lines, assemble top and bottom trunnions

19

together with trunnion seal

22

and bearing

23

. Apply Threadlocker and Sealer to the threads of bolt

20

, torque tighten trunnion retaining bolts

20

to 98 Nm (72 lbf ft).

4

Lightly oil the inner wheel bearing race. Assemble the bearing cup and bearing race

17

into the bearing carrier

15.

5

Fit a new combination seal

18

into the bearing carrier

15

so that the chamfer faces the hub swivel. Do not disassemble seal or use excessive force when fitting.

Do not lub ric at e b efore fit t ing. Use servic e t ool

(892/00891) and spacer to drive the seal squarely into the carrier until flush.

6

Lightly oil the outer wheel bearing race. Assemble the bearing cup and bearing race

16

into the bearing carrier

15

. Fit bearing carrier assembly onto axle stub.

Note

: The bearing carrier must be fully supported during the fitting operation; do not allow any weight to rest on the bearings, otherwise the inner bearing will be displaced and damage the seal.

7

Alig n relat io nship m ark s m ad e o n d ism ant ling .

Assemble the annulus ring

13

to the annulus carrier

12

.

Secure with circlip

14

.

8

Fit annulus assembly in the same angular position as removal, fit retaining plate

11

using new bolts

10

. Do not fully tighten bolts but allow the bearing carrier to rock slightly.

Note:

Steps 10 to 12 describe measurement of rolling force.

To measure rolling torque (simplified process), a special tool is required. See

Service Tools

in this section.

9

Measure seal drag rolling force as follows:

a

Refit the planet gear carrier

2

— DO NOT FIT THE

SUN GEAR

8

.

b

Use a spring balance and cord wrapped around planet gear carrier

2

as shown. Pull the spring balance so that the hub rotates, do several times to let the seal bed in and record the reading.

Remove planet gear carrier

2.

10

Torque tighten bolts

10

evenly to 166 Nm (122 lb ft,

17 kgf).

11

Measure the rolling force as follows:

a

Refit the planet gear carrier

2

— DO NOT FIT THE

SUN GEAR

8

. Use a spring balance and cord wrapped around the planet carrier as shown. Pull the spring balance so that the hub rotates and record the reading.

b

To get the rolling force, subtract seal drag rolling force (see step

9

) from reading obtained at this step, the result should be 64 to 117N (14 to 26 lbf).

c

If the resulting figure is outside these limits, check: the seal is fitted correctly; and/or renew bearings if nec essary; and / o r new f it t ed c o m p o nent s.

Remove planet gear carrier

2

.

12

Press the drive shaft thrust pad

6

(chamfered side lowermost) into the recess in the planet carrier

2

.

13

Fit new p lanet gears

4

in p lac e of any t hat w ere removed.

14

Slide the sun gear

8

(chamfer to be inboard) onto the drive shaft

26

and secure with circlip

7

. Fit a new ‘O’ ring

3

in place of the one discarded during dismantling.

15

Fit the planet carrier

2

onto the bearing carrier

15

ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and tighten screws

1

after applying Threadlocker and Sealer to the threads.

Torque tighten screws to 56 Nm (41 lb ft).

16

Fill hubs with correct grade oil.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

93 — 1

www.WorkshopManuals.co.uk

Transmission

Rear Axle — PD70

Section F

93 — 1

Hub-Dismantling & Assembly

The procedures for dismantling and assembling the hub on a

PD70 axle are virtually the same as for a SD80 axle described on the previous pages (F/92-1 to F/92-4).

However, note that the wheel bearing carrier (shown as item

15

on page F/92-1) is mounted directly on to the axle arm.

Disregard references to the hub carrier (shown as item

21

on page F/92-1).

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 1 Rear Axle — SD80, PD70

Drive Head-Dismantling

As the drivehead cannot be dismantled whilst fitted on the machine, we recommend that the complete axle is removed.

See

Brakes

and

Hub and Driveshaft

for axle arm removal procedure.

The crownwheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential case halves are also matched as are the differential side gears and planet gears, do not use unmatched halves or gears.

1

Position the drive head as shown, with the crownwheel at the top.

2

2

Match — mark the brake piston housing and drive head.

Pull off the brake piston housing.

3

Drive out the differential side nut locking pin, to allow readjustment on assembly. Remove the other brake piston housing only if damaged, but remove its locking p in reg ard less (t o allo w sid elo ad ad just m ent o n assembly).

3

Section F

94 — 1

1

S256050

S256060

4

Lift out the crownwheel/differential assembly.

Note

: If both brake piston housings are to be removed, mark the crownwheel end of the drive head casing to ensure that the assembly is returned to its original position.

4

S256070

5

Using a soft faced hammer, hit the pinion end shaft until the pinion is free from its front bearing, then withdraw the pinion.

6

Withdraw the pinion seal and outer bearing cone.

7

If necessary, drive out the pinion inner bearing cup and shims. Discard the shims. Repeat for the outer bearing cup if required. Note that there are no shims for the outer bearing cup.

9803/3280

5

7

S256080

Purchased from www.WorkshopManuals.co.uk

7

7

6

6

Issue 1

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 2 Rear Axle — SD80, PD70

Drive Head-Dismantling (cont’d)

8

Remove the pinion spacer.

9

Pull off the bearing cone.

9

Section F

94 — 2

8

S256080

10

To dismantle the differential assembly, first remove bolts.

11

Lift off the top half housing.

12

Remove the differential gears and spherical washers. Pull off both differential bearing cones.

0

!

@

@

S256100

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 3 Rear Axle — SD80, PD70

Drive Head-Assembly

Pinion Depth

Determine the pinion depth setting as follows:

Note:

See p age

Crow nw heel and Pinion

for general guidance on crownwheel and pinion adjustment.

1

Assemble the pinion inner bearing and its cup on a flat surface.

2

Place Service Tool 892/00174 over the bearing assembly.

Measure gap

A

. Add tool depth (30.01 mm) to gap

A

to give bearing depth.

3

Note the mounting distance figure

B

etched on the pinion and the deviation figure

C

on the drive head housing.

Both figures are in units of 0.01 mm.

Note

: The pinion depth may be etched on the gear face

B

or on the rear of a gear tooth

D

.

D

B

4

If dimension

B

is

positive

,

add

it to the bearing depth. If dimension

B

is

negative

,

subtract

it from the bearing depth.

5

If dimension

C

is

positive

,

subtract

it from the total. If dimension

C

is

negative

,

add

it to the total.

6

Subtract the result from the standard value of 31.19 mm to give the required shim thickness.

Example (Dimensions in mm)

Dimension

A

Add tool depth

Total

0.25

+ 30.01

30.26

Add dimension

B

if positive.

(Subtract if negative.)

Total

+ 0.01

30.27

Add dimension

C

if negative.

(Subtract if positive.)

Total

+ 0.01

30.28

Standard Value 31.19

Less calculated total from above — 30.28

SHIM THICKNESS 0.91

C

Section F

94 — 3

S184400

S256110

S256120

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 4 Rear Axle — SD80, PD70

Drive Head-Assembly (cont’d)

Note:

The crown wheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential housing halves are also matched.

Do no t use unm at c hed halves. If req uired , f it a new crownwheel to the differential case half, torque tighten crownwheel retaining bolts to 166 Nm 122 lbf ft; 17 kgf m).

7

Assemble the differential gears and their spherical washers into the bottom half housing. Fit the differential bearing cones.

8

Position the top half housing onto the differential, aligning the match mark letters (see Note above). Apply

JCB Threadlocker & Sealer to the threads of bolts, then fit and torque — tighten to 56 Nm (42 lbf ft, 6 kgf m).

Check the gears for free rotation.

7

7

8

8

Section F

94 — 4

S256100

9

Fit t he p inion inner b earing c one and t he largest available spacer (e.g. 14.20 mm)

Note

: It should be noted that the axle should be assembled using a solid spacer. However, in the absence of the special tools required or the correct size solid spacer it is acceptable to fit a collapsible spacer, refer to

Axles

,

Collapsible Spacer

Assembly

.

9

9

S256090

10

Fit the pinion inner bearing cup, together with the required thickness of shims to give correct pinion depth, see Pinion Depth, steps 1 to 6. To ensure the cup is fitted square, use a suitable puller assembly. Do not use a hammer. Fit the outer bearing cup.

11

Insert the pinion into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code num b ers et c hed on t he p inion end fac e and t he crownwheel perimeter should be the same.

12

Fit the pinion outer bearing cone. Do not fit the oil seal at this stage.

S256080

!

0

0

0

@

@

9803/3280

Purchased from www.WorkshopManuals.co.uk

S256120

Issue 1

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 5 Rear Axle — SD80, PD70

Drive Head-Assembly (cont’d)

13

Fit sp ec ial t ool sleeve

B

and sp ec ial p inion shaft adapter

C

. Tighten adapter

C

to approximately 50 Nm, making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing. If the pinion is not free to rotate or there is no end float at this stage check the bearing is fitted correctly. Also check the correct size spacer has been fitted.

14

Fit special bracket

D

to the drive-head housing using two M10 x 30 nuts and bolts. Fit special tool support pillar

E

to bracket

D

so that the fork end engages in adapter

C

. Ensure that fork

E

is centrally located on adapter

C

. If necessary, re-align bracket

D

to suit.

Fit dial test indicator (DTI)

F

. Ensure that the DTI is mounted on the drive head and not on bracket

D

.

D

C

B

15

Set torque wrench

G

to 35 Nm (25.8 lbf ft) and measure the end float while rotating the shaft.

16

To select the right size spacer, subtract the end float obtained at step 14 from the solid spacer size (14.20

mm). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted from the solid spacer setting kit. If there is no spacer of this size, fit the next nearest size spacer, refer to

Service Tools — Axles

.

Example

Temporary spacer size

Subtract end-float

Total

14.20

0.25

13.95

Subtract tolerance & preload

Result

0.04

13.91

(No spacer available this size, use next nearest size spacer i.e 13.900)

17

Remove sleeve

B

and temporary spacer. fit correct size spacer from solid spacer setting kit, refer to

Service

Tools — Axles

. During removal take care to avoid damaging the outer bearing.

18

Fit sleeve

B.

Tighten adapter

C

to no more than 50 Nm t o p rot ec t against b earing d amage w hile sp ac er selection is verified making sure the pinion is free to rotate. Check there is no end float and pinion is free to turn smoothly by hand. Remove adapter

C

and fit nut

16.

Then check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly.

Note:

If the pinion is not free to rotate check the correct size spacer has been fitted.

G

E

F

A396970

Section F

94 — 5

A396850

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 6 Rear Axle — SD80, PD70

19

If rolling torque measured at step 18 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly.

20

Remove adapter

C

and sleeve

B

. Fit a new oil seal, grease between seal lips before fitting. Fit the brake calliper bracket

D

. Apply JCB Threadlocker and Sealer to the fixing bolts

E

. Fit the brake disc/coupling and a

NEW stake nut

16

.

^

21

Progressively torque tighten the stake nut, occasionally rotating coupling yoke, up to 250 Nm. Providing the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.

Note:

The nut tightening torque can be increased to a maximum of 300 Nm provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm.

22

Finally stake the nut

16

into the slot.

C

B

20

E

D

Section F

94 — 6

A401240

23

If both brake piston housings were removed, fit the one at the opposite end to the crownwheel, using the procedure in Step 24. Then install the crownwheel

/differential assembly into the drive head.

S256070

24

Apply JCB Multi-Gasket to the drive head mating face, then fit the brake piston housing. Ensure that the match

— marks mad e d uring d ismant ling are aligned . Fit capscrews. Torque — tighten to 56 Nm (42 lbf ft, 5.7 kgf m). (Applies to both piston housings.)

25

Adjust differential side nuts to give a bearing preload of

1.13-2.26 Nm (0.8-1.6 lbf ft; 0.1-0.2 kgf m). (Measure the preload by taking another rolling torque reading and subtracting the torque figure measured at step 21. The difference is the bearing preload.)

9803/3280

*

Purchased from www.WorkshopManuals.co.uk

&

$

S256140

Issue 1

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 7 Rear Axle — SD80, PD70

26

Measure the crownwheel backlash, which should be

0.17-0.28 mm (0.006-0.010 in). Adjust the differential side nuts by equal amounts when altering backlash.

When backlash and preload are both correct, fit the sidenut locking pins, see step 25.

Section F

94 — 7

S256150

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

www.WorkshopManuals.co.uk

Transmission

94 — 8 Rear Axle — SD80, PD70

Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion.

The marking will then be transferred to the crown wheel teeth.

Section F

94 — 8

Correct tooth marking.

A386940

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel towards the pinion to correct the backlash.

A386950

Pinion too far out of mesh.

Increase the shim thickness between the pinion inner bearing cup and the axle casing. Move the crown wheel away from the pinion to correct the backlash.

9803/3280

Purchased from www.WorkshopManuals.co.uk

A386960

Issue 1

Section F

95 — 1

www.WorkshopManuals.co.uk

Transmission

Axles

Section F

95 — 1

Collapsible Spacer Assembly

When assembling the axle, if the special tools listed in the

Service Tools — Axles

section or if the correct size solid spacer is not available it is acceptable to fit a collapsible spacer using the procedure below. The illustration shows a typical axle, note that rear axles are fitted with a brake disc, not the yoke 22 shown.

1

Smear output shaft inner bearing

27

with JCB HP

Grease before refitting. Fit bearing cup

28

over pinion shaft

23

and assemble into drive head casing.

2

Fit NEW collapsible spacer

24

, after smearing with JCB

HP Grease fit outer bearing

26

followed by a new oil seal

25

. Grease between seal lips before fitting. Assemble yoke

22

and NEW stake nut

20

with integral washer.

3

Tighten stake nut to achieve a rolling torque of 1.5 to 2.8

Nm (1.1 to 21. lbf ft), inclusive of seal drag.

Note:

If this figure is accidentally exceeded the output shaft must be dismantled and the collapsible spacer

24

renewed.

4

Finally stake nut into slot.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

100 — 1

www.WorkshopManuals.co.uk

Transmission

Limited Slip Differential

Section F

100 — 1

1

5

6

7

8

9

10

3

12

13

14

10

9

8

7

6

11

4

2

S212800

9803/3280

S212790

Purchased from www.WorkshopManuals.co.uk

S171530

Issue 1

Section F

100 — 2

www.WorkshopManuals.co.uk

Transmission

Limited Slip Differential

Section F

100 — 2

Dismantling and Assembly

The numeric al seq uenc e show n on t he illust rat ion is intended as a guide to dismantling

When Dismantling

Mark the two differential halves before dismantling, for subsequent assembly.

Note the relative positions of the friction and counter plates b ef o re d ism ant ling , t hey m ust b e f it t ed in t he sam e positions.

If worn, the friction and counter plates must be renewed as a complete set.

When Assembling

1

Assemble trunnion pins

12

, side gears

11

with pressure plates

10

, counter plates

8

, friction plates

9

, planet gears

13

and thrust washers

14

into the ‘crownwheel half of the differential assembly

5

.

Note:

Do not fit the shims

6

at this point.

2

Align the two halves of the differential assembly with the marks made during dismantling. Assemble using bolts

3

.

3

Using a dial test indicator (or feeler gauges), with two screwdrivers or suitable levers, gently apply pressure to side gear

11

away from the trunnion pins

12

as shown.

Measure and note the end-float of the side gear.

4

Turn the differential assembly over and repeat step 3 for the second side gear.

5

Dismantle the differential assembly. Add shims

6

to give end- float between 0.1 and 0.2mm (0.004 and

0.008in.).

N ot e

: Shim m ing m ust b e c arried o ut w henever t he differential is dismantled, however the end float 0.1 and 0.2

mm (0.004 and 0.008 in.) can be exceeded on previously assembled differential as this is only an initial setting figure which allows for bedding in.

6

Repeat steps 2, 3, and 4. If the end float is correct, tighten bolts

3

to 56 Nm (41 lbf ft).

7

Fit crownwheel

2

using new Verbus Ripp bolts

1

.

Friction Plate Wear Limits

Measure and note the thickness of the friction plate, the result must not be less than 1.25 mm (0.049 in).

Check the condition of the friction material, which should be even over both surfaces.

If in doubt, discard the set (friction and counter plates).

Torque Settings

SD55

Item 1

94 Nm

SD70, PD70, SD80

Item 1

166 Nm

9.6 kgf m

16.9 kgf m

70 lbf ft

122 lbf ft

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

105 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

105 — 1

Removal and Replacement a

J

J

J J

N

M

R

M

R

P

K

L

X

S

F

G

G

E a b b

H

H

A c

D

9803/3280

c d d

Z

B

Purchased from www.WorkshopManuals.co.uk

A401310

Y

Issue 1

Section F

105 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

105 — 2

Removal and Replacement (cont’d)

IMPORTANT: The gearbox is heavy. Unless it is safely supported during removal and replacement it could fall and cause injury. Make sure that you have access to suitable jacks and a gearbox locating ‘cradle’ before attempting to remove the gearbox.

!

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.

GEN 1-1

Removal

1

Park the machine on firm level ground. The gearbox is heavy. If the ground is soft or uneven it will not be possible to remove the gearbox safely.

2

Loosen the right side rear wheel nuts. Rest the shovel on the ground and lower the stabilisers to raise the rear of the machine. Check dimension

X

which must be at least 800 mm. This will allow the gearbox to be pulled clear. Block/support the machine.

Note:

On sideshift machines, suitable lengths of steel channel can be used as safety struts between the stabiliser feet and chassis, one at each stabiliser.

3

Remove the right hand side rear wheel.

4

Remove the bonnet — see Section 3,

Routine

Maintenance

.

5

Disconnect the gearshift from the top of the gearbox, as shown at

A

.

6

Remove the rear axle propshaft — see

Propshafts

.

7

Disconnect the front axle driveshaft bolts

B

(use tool

892/00822).

8

Drain the hydraulic tank and remove the main hydraulic pump (see Section E,

Service Procedures and Main

Hydraulic Pump

). Tie the suction hose up clear of the gearbox.

9

Drain the gearbox oil, see Section 3,

Routine

Maintenance

.

10

Remove the access bung/plate at the bottom of the torque converter housing. Through the access hole, loosen and remove the torque converter to engine flywheel retaining bolts

D

.

11

At a later stage the gearbox and engine assembly is tilted to allow access to fixing bolts. To prevent damage as the engine is tilted components must have their fixings removed as follows:

a

Fuel sediment bowl assembly

E

(2 bolts).

b

Exhaust stack fixing bracket

F

(2 bolts).

d

Radiator fan cowl

G

(4 bolts).

It is not necessary to remove these components, only release them from their fixings.

12

Support the gearbox using a suitable trolley jack and cradle. The gearbox must be securely located on the cradle as shown at

Y

.

13

Make sure that the weight of the gearbox is supported by the trolley jack and then remove the gearbox mounting bolts

H

.

14

Using the trolley jack, lower the gearbox and engine to gain access to the top torque converter housing to engine block retaining bolts

J

. Put a support under the engine as shown at

Z

to prevent it from dropping when the gearbox is removed.

15

Undo the four bolts

J

at the top of the torque converter housing. Note that the two outer most bolts have nuts instead of screwing into the engine block. Also note the position of the electrical earth straps.

16

Pull off the breather tube

K

. Undo the gearbox dipstick fixing nut

L

and then remove the dipstick tube.

17

Uncouple the forward/reverse solenoid valve connectors

M

, oil pressure sender

N

and temperature sender

P

(if fitted). Label the connectors for identification when refitting.

18

Disconnect the gearbox oil cooler hoses

R

.

19

On 4 wheel drive machines, uncouple the electrical connector at the 4WD solenoid

S

.

20

Remove the flywheel housing to engine bolts

T.

21

Manoeuvre the gearbox with the torque convertor clear of the engine housing.

22

Lower the trolley jack and pull the gearbox and torque convertor clear of the machine.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

105 — 3

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

105 — 3

Removal and Replacement (cont’d) a

J

J

J J

L

M

M

N

P

S

K

X

F

G

G

E a b b

H

H

A c

D

9803/3280

d c d

Z

B

Purchased from www.WorkshopManuals.co.uk

T

A401310

Y

Issue 1

Section F

105 — 4

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

105 — 4

Removal and Replacement (cont’d)

Replacement

Replacement is a reversal of the removal procedure but note the following:

1

Before replacing the gearbox remove circlip

5

and withdraw the pump driveshaft

6

together with its bearing

7

approximately 50 mm (2.0 in). The shaft can then be engaged after the gearbox has been fitted, making replacing the gearbox easier. Remember to engage the pump drive shaft, refit the bearing and circlip after the gearbox has been fitted.

2

Set the torque converter as described in

Torque

Converter, Removal and Replacement

.

3 Align the Torque Converter

It is vitally important that the torque converter is fitted at the gearbox and engine flywheel correctly

.

Failure to locate the converter correctly will result in damage to the gearbox oil pump on engine start up.

Proceed as follows:

Make sure that the torque converter drive dogs

1

are correctly engaged with the pump

2

on the gearbox.

Temporarily tie the converter onto the gearbox. Use wire tied at a drive plate bolt hole to a convenient point on the outside of the gearbox.

Take note of the flywheel and drive plate fixing hole phasing. The heads of the bolts

3

will foul the flywheel

4

if phasing is incorrect.

Before bolting the torque converter housing to the engine make sure the mating faces are fully together

(DO NOT USE FORCE). The drive plate

8

should also be mated close to the flywheel. Do not force the components together with the fixing bolts.

Make sure that the torque converter is free to rotate slightly within the clearance of the location bolt holes. If you cannot rotate the converter it is trapped either by bolt heads

3

or by incorrectly located pump drive dogs.

Make sure that all is well before tightening the bolts.

4

Fill the gearbox with the specified amount and type of oil (see

Section 3, Routine Maintenance

). Leave hose

N

off until the filling operation is complete. After filling refit hose

N

.

Torque Settings

Item

B

D

H

J,T

Nm

79

44

237

98

kgf m lbf ft

8 58

4.5

32

24

10

175

72

1

2

5

6

7

4

8

3

A396460

A396890

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

110 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 1

Dismantling

Cleanliness is of the utmost importance when servicing the gearbox. All precautions to prevent any ingress of dirt, grit etc. must be taken. To this end wash the exterior of the gearbox assembly as follows;

Make sure that all open ports and orifices are effectively plugged. Remove any deposits of dirt, grit and oil from the outer casings using a suitable degreaser and water. Dry the casings.

Note:

For details of service tools refered to, see

Service

Tools

at the front of this section.

Note:

If the main hydraulic pump has not been removed, remove it. Support the pump, undo the 2 fixing bolts

A

and then withdraw the pump from the gearbox.

A

A

A388030

1

Remove t he c irc lip and t hen w it hd raw t he p ump driveshaft

1a

together with its bearing

1b

.

2

Remove and discard the shaft sealing ring.

1

2

1b

1a

A388040

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

110 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 2

Dismantling (cont’d)

3

Drain the oil from the casing by removing the suction strainer

3a

. Remove and discard the oil filter

3b

.

3a

3b

4

If the gearbox is fitted with a 2/4 wheel drive unit

B

, remove it. For the correct procedure see

Hydraulic 2/4 wheel Drive Unit, Dismantling

.

5

Unscrew bolts and withdraw pump.

6

Remove and discard pump sealing ring.

7

Sep arat e p ump c omp onent s. Not e t hat t he p ump components are held together with a security screw at the rear of the assembly.

8

Remove and discard oil seal from pump housing.

5

7

6

B

A395360

9803/3280

8

Purchased from www.WorkshopManuals.co.uk

221021

Issue 1

Section F

110 — 3

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 3

Dismantling (cont’d)

Position transmission vertically, standing on the face of the torque converter housing.

9

Unscrew capscrews and remove solenoid control valve.

Note ‘O’ rings fitted around ports on mating face of solenoid valve body.

Note:

See

Service Procedures

,

Forward/Reverse Control

Valve

for solenoid dismantle/assembly .

10

On 4 wheel drive transmissions remove the 4 wheel drive hydraulic pipe and control valve

10a

.

11

Undo the 4 bolts and remove the gear lever turret.

Remove the baffle plate beneath if fitted. If necessary the turret assembly can be dismantled as follows:

a

Slacken worm drive clips and remove rubber boot.

b

Using a suitable press or clamp, carefully press the top lever

11a

down to compress spring

11b

, just enough to release pressure on circlip

11c

.

Note:

BEWARE of spring pressure acting on nylon seat when circlip is removed.

c

Remove circlip

11c

.

d

Slowly release the pressure from the top lever

11a

and remove it, together with bush

11d

, washer

11e

and spring

11b

.

e

Rotate spring

11c

so as to disengage from the retaining tabs inside the turret

11

. Be aware that the spring may suddenly disengage while still under pressure. Repeat this operation until all the coils are disengaged and the spring can be removed.

f

Remove retainer

11f

and bottom lever

11g

.

11

11c 11d 11a 11e 11b

10a

10

A387950

9

11

9803/3280

11g 11f 11c

A388210

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

110 — 4

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 4

Dismantling (cont’d)

12

Unscrew plug and withdraw pressure maintenance valve spool and spring.

13

Unscrew four bolts and remove pressure maintenance valve body. Remove and discard gasket.

12

13

14

Remove the torque converter pressure relief valve ball and spring assembly

14a

. Remove the torque converter pressure regulating valve spool and spring assembly

14b

.

15

Unscrew bolts and lift off output end casing

15a

. Be sure to retrieve bearing outer cups from inside the casing. Keep the cups together with their associated bearing.

A387960

15a

15

14a

9803/3280

14b

Purchased from www.WorkshopManuals.co.uk

A387970

Issue 1

Section F

110 — 5

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 5

Dismantling (cont’d)

16

Unscrew selector detent plugs.

17

Remove selector detent balls and springs.

18

Unscrew selector fork retaining screws and lift out selector rods.

19

Note that the selector forks are not interchangeable.

Mark the forks to ensure they are replaced correctly.

Remove selector forks.

19

18

16

17

221080

20

Push out the interlock plunger on disassembly.

21

Lift off 3rd/4th synchro-hub. Note the positions for refitting with mating cups.

22

Lift out layshaft assembly .

22

21

20

S395460

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

110 — 6

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 6

Dismantling (cont’d)

23

Remove idler gear upper thrust washers and bearing.

Keep the thrust washers and bearing together.

24

Tilt mainshaft

L

to one side and lift off idler gear together with its needle roller bearing

24a

.

25

Remove idler gear lower thrust washers and bearing.

Keep the thrust washers and bearing together.

26

Lift off idler gear spacer.

27

Tilt mainshaft

L

to one side and lift out the forward/reverse assembly. Discard sealing rings.

Note:

See

2/4 Wheel Drive Clutch

for forward/reverse unit dismantling and assembly procedures.

28

Remove mainshaft

L

.

*

29

The idler gear spindle is a press fit in the casing. Use a suitable puller screwed into the 1/2in. B.S.P. hole in the end of the spindle for extraction. Note that the spindle should only be removed if it is damaged and is required to be replaced.

23

24

24a

25

29

L

26

27

S407370

30

30a

30

Unstake the nut. Whilst holding the output yoke with service tool 892/00812, unscrew output shaft nut and remove the washer

30a

beneath. Support output shaft from beneath and lift off the yoke

30b

.

31

Withdraw output shaft assembly and lift out outer bearing

31a

. Remove spacer

N

and retain for assembly.

32

Prise out oil seal and discard.

33

Using a suitable puller, withdraw output shaft inner bearing. Remove the mainshaft bearing outer cup

33a

from the centre of the output shaft transfer gear.

30b

32

31a

9803/3280

N

31

33

33a

Purchased from www.WorkshopManuals.co.uk

A388000

Issue 2*

Section F

110 — 7

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 7

Dismantling (cont’d)

Mainshaft

34

Using service tool 892/00179 and adapter 992/06300 pull off 3rd gear together with synchro cup

34a

, gear

34b

, spacer washer

34c

, oil retention washer

34d

and bearing

34e

. Keep the synchro hubs and cups in their original relationship.

35

Remove needle roller bearings

35

.

36

Remove bearing from converter end of mainshaft using press 892/00179.

34e

34d 34c 34b 34a 34d 35

36

Layshaft

37

Remove the bearing

37

. Remove 4WD transfer gear

37b

and bearing

37a

from layshaft. On 2WD machines a spacer is fitted in place of the transfer gear.

38

Lift off 1st gear.

39

Remove 1st gear needle roller bearings.

40

Note that the 1st/2nd synchro unit

40

is of a different design to the 3rd/4th gear unit. There are components which may be lost during removal unless care is taken.

Hold the unit together with the synchro cones on each side and lift off. Keep the synchro cones, rings and hubs in their original relationship.

*

41

Use a press to push off 2nd gear

41a

, synchro assembly

40

and 1st gear needle roller track ring

41b

.

42

Remove 2nd gear needle roller bearings.

37

42 41a

40 41b 39 38 37b 37a

A395470

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

110 — 8

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

110 — 8

Dismantling (cont’d)

Setting Ring Removal

The mainshaft and layshaft end float is controlled by a threaded ‘setting ring’ screwed into the casing.

To enable access to the mainshaft setting ring the torque converter housing must be removed. Undo the 12 fixing bolts

X

and remove the housing. The setting ring is located at position

B

.

To enable access to the layshaft setting ring the bearing cover must be removed. Undo the 4 fixing bolts

Y

, remove the cover and discard the gasket beneath. The setting ring is located at position

C

.

If the bearings or shaft are to be renewed the associated setting ring must be removed and discarded as follows:

1

Carefully prise out the staked section of the ring

Z

clear of the casing.

2

Using the special socket adaptor, unscrew and discard the ring. (Use adaptor 892/01080 for the layshaft ring and 892/01079 for the mainshaft.)

3

Be sure to remove any shards of metal that may have fallen into the casing.

Note:

Once removed, the setting rings must not be re-used.

Discard the ring and obtain a new one. Note that the mainshaft and layshaft setting rings are not interchangeable.

Y

X

C

B

388330

A388320

Z

A388230

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

111 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

111 — 1

G

A1

A2

C

X

B2

B1

Y

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

111 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

111 — 2

Inspection

Before assembling the gearbox make sure that a thorough inspection of all components is carried out. Remember that although a failed component may be easy to identify, the cause of that failure may be less easy to trace. It is also possible that a failed component may have caused damage to other areas of the gearbox.

1

Carefully remove all traces of gasket compound from components as follows:

a

Front and rear casing mating faces.

b

Front casing and torque converter housing mating faces.

2

Clean t he insid e of t he c asings using a suit ab le degreasing agent.

3

Carefully inspect all gears, bearing and shafts for signs of excessive wear or damage. If wear or damage is evident, components must be renewed.

4

Make sure that all oil way cross drillings in the casings, shafts and gears are clear and free from debris. Blocked oil ways are a common cause of bearing failure. Use an air line to blow through cross drillings.

Note:

If failure of the forward/reverse or 4 wheel drive clutch is suspected see the relevant dismantling and assembly procedure in this section.

1st/2nd Gear Synchromesh Unit

The 1st/2nd gear synchro unit must be checked for wear before assembly as follows:

1

Before d ismant ling t he unit b e aw are t hat on reassembly, the components must be kept in their original relationships.

2

Dismantle the unit by removing the cones and rings

A1

,

A2

and

B1

,

B2

. Push off the sleeve

C

taking care to retrieve the sets of balls

D

, poppets

E

and springs

F

.

3

Inspect the mating faces of cones and rings. The wear indicator grooves

X

must still be visible. As a further check, locate the cones and rings together (as shown at

Y

) and measure the clearance between them using feeler gauges. The clearance should be between 0.5

and 1.9 mm for both

A

and

B

pairs. If either is out side these limits then the complete synchro unit must be renewed.

4

Inspect the teeth on all cones and rings for excessive wear or damage. If wear or damage is evident the unit must be renewed.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

112 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 1

Assembly

Bearing Setting Rings

If the bearing outer cups and setting rings have been removed, fit new rings so that they are flush with the outer face of case as shown at

A

. Press in the outer bearing cups from the inside of the casing as shown at

B

. Push in the cup until it is up against the setting ring.

A

A388250

Casings

If the gearbox casings are to be renewed, be sure to fit blanking plugs and adapters as required. Inspect the original casings and identify the blanking plug and adapter positions.

Transfer the plugs and adapters to the new casings. Apply

JCB Threadlocker and Sealer to the threads.

Note that new plugs may be supplied with a sealant ‘patch’, in which case sealant need not be applied. Torque tighten plugs to 25 — 28 Nm (18.4 — 20 lbf ft).

Before fitting adapter

C

, be sure to fit the orifice restrictor inside the port.

9803/3280

B

S407550

C

Purchased from www.WorkshopManuals.co.uk

A388420

Issue 3*

Section F

112 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 2

Gearbox — Assembly (cont’d)

If the torque converter housing has been removed, temporarily replace it. The gearbox can again be positioned standing on the face of the housing ready for assembly.

Layshaft Assembly

1

Smear bearing surface of shaft with JCB HP Grease and fit needle roller bearings

1a

(wider bearing first), followed by 2nd gear

1b

.

*

2

Fit the synchro assembly

2

, then press fit the bearing track

3a

.

3

Slide 1st gear needle roller bearings

3b

over the track.

Smear bearings with oil. Fit 1st gear

3c

over needle roller bearings.

*

4

Assemble 4WD transfer gear

4

over splines. On 2WD machines slide spacer over splines.

5

Press bearing

5a

and

5b

onto the assembled layshaft.

Smear the bearings with JCB HP Grease.

5b 1a 1b

2 3a 3b 3c 4 5a

A395470

Mainshaft Assembly

6

Smear bearing surface of mainshaft with JCB HP

Grease. Fit the needle roller bearings

6a

and

6b

.

Assemble 3rd gear

6c

and synchro-cup

6d

. Fit synchro gear

6e

.

7

Fit spacer washer

7a

and oil retention washer

7b

. Note the correct way round of components

7a

and

7b

. Press bearing

7c

onto shaft and smear with JCB HP Grease.

8

Press bearing onto assembled mainshaft and smear bearing with JCB HP Grease.

7c 7b 7a 6e 6d 6c

6b 6a

8

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

112 — 3

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 3

Assembly (cont’d)

9 Transfer Gear/Output Shaft Assembly

Note

: Make sure that the layshaft bearing outer cup is fitted to the rear casing before fitting the transfer gear/output shaft.

a

Liberally coat output shaft inner bearing with JCB

HP Grease before fitting inner bearing

P

.

b

Fit the service solid spacer

N

(13.70 mm) over output shaft and assemble into casing.

c

Lightly oil output shaft outer bearing and cup

R

and fit to output shaft, do not fit oil seal

S

at this stage.

S

R

N

P

10 a

Fit special tool sleeve

A

which temporarily replaces the output yoke and secure with special tool nut

B

, torque tighten to 50 Nm (36.9 lbf ft).

Note

: Check for end float while tightening nut

B

, if there is no end float check:

The bearing cups are pushed fully into the casing.

The correct bearings are fitted, check parts catalogue.

The solid spacer

N

is 13.70 mm.

b

Ensure that the layshaft setting ring is slightly below layshft cover facing on the rear case. Fit special tool support pillar

C

(892/01076) so that the fork end engages in special tool nut

B

, tighten bolt

D

.

B

A

C

D

A388000

9803/3280

Purchased from www.WorkshopManuals.co.uk

A396650

Issue 1

Section F

112 — 4

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 4

Assembly (cont’d)

11 a

Fit dial test indicator

E

(DTI) .

b

Set torque wrench

F

to 35 Nm and measure the end float while rotating the output shaft.

c

To select the right size spacer, subtract the end float obtained at step

11b

from the solid spacer

(13.70 mm). Also subtract 0.120 mm to allow for theoretical bearing tolerance and pre load. If there is no spacer of this size, fit the next smallest spacer.

Example

Service spacer

Subtract end float

Total

Subtract tolerance & preload

Result

Use next smallest spacer ie.

13.70

0.41

13.29

0.12

13.17

13.15

d

Remove special nut

B

and sleeve

A

. Remove rear bearing and 13.70 mm spacer. Fit correct size spacer (Do no fit the oil seal at this stage). Take care to avoid damaging the outer bearing.

e

Fit sleeve

A

and initially tighten nut

B

to 50 Nm (36.9

lbf ft). Check there is no end float and rolling torque less than 1.5 Nm (1.0 lbf ft). If the rolling torque exceeds 1.5 Nm (1.0 lbf ft) check that the output shaft has been assembled correctly.

f

If the rolling torque measured is too high, fit the next larger size spacer. If there is end float, fit the next smaller size spacer.

B

A

F

C

D

E

A396650

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

112 — 5

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 5

Assembly (cont’d)

12 a

Remove nut

B

and sleeve

A

. Fit new oil seal

S

, grease between seal lips before fitting. Note that the seal does not fix to the back of the housing — use servicel tool to locate the seal. Fit the output yoke

Y

.

b

Fit the stepped washer

W

the correct way round with the plain face uppermost as shown.

c

Fit NEW retaining nut

T

and progressively torque tighten to 300 Nm (221 lbf ft). Provided the correct size spacer has been selected, the rolling torque should be 2.0 Nm (1.5 lbf ft) when nut

T

is fully torque tightened.

Note:

If the rolling torque measured is too high, fit the next larger size spacer. If the rolling torque is too low, fit the next smaller size spacer.

d

Finally, carefully stake nut

T

into slot using a square-ended staking tool.

13

Press idler gear spindle into front casing.

Note:

Before proceding further, make sure that the 3 shaft front bearing outer cups are correctly located inside the casing

V

.

14

Grease forward reverse shaft front bearing, then carefully lower forward/reverse unit into casing. Fit the shaft sealing rings and smear with grease.

V

Y

W

T

S

13

A388180

14

221180

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

112 — 6

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 6

Assembly (cont’d)

15

Smear mainshaft output end bearing with JCB HP

Grease and place mainshaft

L

in position, followed by the forward/reverse assembly

M.

16

Fit idler gear spacer.

*

17

Fit thrust washers and bearing assembly. Lubricate and fit the needle roller bearing

17a

.

18

Fit synchro cone to 3rd gear (mainshaft

L

). Fit the idler gear

18a

to the spindle whilst tilting mainshaft

L

to one side.

*

19

Fit thrust washers and bearing assembly.

18

19

18a

17a

17

16

L

M

20

Smear front end bearing of layshaft with JCB HP

Grease, and carefully lower layshaft into position.

21

If re-using synchro assembly fit the parts in their original positions.

22

Using a suitable wire support locate interlock plunger into its bore. A smear of grease will hold the plunger in position. If required, access is available via a

1

/

4

BSP side drilling.

20

21a

21

S407370

22

9803/3280

Purchased from www.WorkshopManuals.co.uk

221090

Issue 2*

Section F

112 — 7

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 7

Assembly (cont’d)

23

Fit selector forks into position.

24

Slide selector rods into position, taking care not to dislodge the interlock plunger. Apply JCB Threadlocker and Sealer to selector fork retaining screws

H

, and tighten to 35 Nm (26 lbf ft).

25

Fit 1st gear selector detent ball and spring at position

A

.

Apply JCB Threadlocker and Sealer to the detent plug

25a

, screw in and tighten.

26

Temporarily fit the 3rd and 4th gear selector detent assembly at position

B

, do not apply sealant to the plug at this stage.

27

Check that each gear engages fully, and that the interlock plunger prevents simultaneous engagement of

2 ratios.

28

Remove the 3rd and 4th gear selector detent assembly from position

B

. Lift the selector rod

J

to select 4th gear. With 4th gear selected, temporarily lock the rod in in position by screwing in service tool 892/01077 at

B

.

Temporarily fit service tool 892/01078 to the torque converter end of mainshaft

M

. If the tool is not available a suitable M8 bolt approximately 100 mm long can be used.

23

23

24

J

M

H

H

H

H

B

A

25

25a

29

Apply a bead of JCB Multigasket to mating face of casing. Insert ‘O’ rings

Z

. Smear grease onto reverser shaft ring seals, and apply JCB HP Grease to bearings prior to fitting output end casing.

Note:

Make sure that the forward/reverse shaft ring seals are in good condition before fitting output end casing.

Z

Z

29

A388010

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

112 — 8

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 8

Assembly (cont’d)

30

Make sure that the 3 bearing outer cups

C

are correctly located; note that 2 cups locate inside the casing and 1 locates in the centre of the output shaft transfer gear

G

.

Carefully lower rear casing into position. Note that the forward/reverse unit shaft engages with the casing first, followed by 3rd/4th gear selector rod. To ensure that the mainshaft locates with the output shaft it will be necessary to push on tool

T

to keep the shaft correctly aligned. Rotate the output shaft

S

back and forth to engage the gears on the layshaft. Do not use excessive force when fitting the casing.

31

Apply JCB Threadocker and Sealer to bolts and torque to 56 Nm (42 lbf ft).

32

Remove service tool at position

B

. Fit the detent ball and spring. Apply JCB Threadlocker and Sealer to selector detent plug, install and tighten.

C

G

C

C

A395340

30

S

31

T

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

112 — 9

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Transmission

Section F

112 — 9

*

Assembly (cont’d)

33 End Float Checking — Forward/Reverse Unit

Measure end float of forward/reverse unit shaft which should be 0.01 to 0.16 mm (0.0004 to 0.006 in).

Note:

Rotate shaft whilst measuring to seat bearings fully.

Position pointer of dial test indicator (DTI) on the chamfer of the shaft, not the end face. This will ensure a constant reading is given.

The forward/reverse shaft and its associated components are manufactured using a ‘Setright’ system. Provided components are assembled correctly the end float will be within the limits given above.

If there is no float, or too much end float, separate the casings and check that the bearings inner and outer cups are fitted correctly. If the forward/reverse shaft and clutch assemblies have been dismantled check that the assembly has been carried out correctly.

S221201

34 End Float Setting — Mainshaft

If the mainshaft, output shaft and/or associated bearings have been renewed, the shaft end float must be reset.

a

Remove the torque converter housing and position the gearbox to gain access to setting ring

A

.

b

Using service tool 892/01079 tighten the setting ring to 25 Nm (18.4 lbf ft) whilst at the same time rotating the shaft via the output yoke (a gear must be engaged). Do not over tighten the ring.

Overtightening will damage the bearings.

c Undo the ring a small amount to obtain a shaft end float of 0.03 to 0.08 mm (0.001 to 0.003 in). To measure the endfloat screw in a bolt (or service tool

892/01078) at the threaded hole in the end of the shaft. Set up a DTI with the probe on the chamfer of the shaft. Zero the DTI. Rotate the shaft and at the same time pull up on the bolt, noting the reading on the DTI. Screw the ring in or out until the end float is correct.

d

When the correct setting has been obtained, stake the setting ring to the casing as shown at

Y

(see the note below). Note that once staked the setting ring can not be used again. If the ring is disturbed it must be discarded and a new one used to re-set the end float.

Note:

If the slots in the setting ring fall close (within zone

Z

) to the staking position

Y

, stake at position

X

instead. In this event the ring must also be folded on one side at position

Y

, fold on the side furthest away from the slot in the ring. This is important as the ring will otherwise restrict the flow of lubrication oil.

X

Z

A

Y

A

X

A396640

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section F

112 — 10

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 10

Assembly (cont’d)

35 End Float Setting — Layshaft

If the layshaft and/or its bearings have been renewed, the shaft end float must be reset.

a

Fit the torque converter housing and stand the gearbox on the housing.

b

Using service tool 892/01079 tighten the setting ring

A

to 25 Nm (18.4 lbf ft) whilst at the same time rotating the shaft via the output yoke (a gear must be engaged). Do not over tighten the ring.

Overtightening will damage the bearings.

c Undo the ring a small amount to obtain a shaft end float of 0.03 to 0.08 mm (0.001 to 0.003 in). To measure the endfloat screw in a bolt (or service tool

892/01078) at the threaded hole in the end of the shaft. Set up a DTI with the probe on the chamfer of the shaft. Zero the DTI. Rotate the shaft and at the same time pull up on the bolt, noting the reading on the DTI. Screw the ring in or out until the end float is correct.

d

When the correct setting has been obtained, stake the setting ring to the casing as shown at the two positions

Y

(see the note below). Note that once staked the setting ring can not be used again. If the ring is disturbed it must be discarded and a new one used to re-set the end float.

Note:

If the slots in the setting ring fall close (within zone

Z

) to the staking positions

Y

, stake at position

X

instead. In this event the ring must also be folded on one side at the two positions

Y

, fold on the side furthest away from the slot in the ring. This is important as the ring will otherwise restrict the flow of lubrication oil.

e

Using a new gasket, refit the layshaft bearing cover.

Apply JCB Threadlocker and Sealer to the fixing bolts and tighten to 56 Nm (42 lbf ft).

X

A

Y

Y

A

Z

X

Z

A396630

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

112 — 11

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 11

Assembly (cont’d)

36

Place new pump sealing ring in position. Make sure that the charge pump drain hole is clear before fitting a new oil seal to the pump housing.

37

Install pump taking care to align mounting holes. Apply

JCB Threadlocker and Sealer to bolts and, using new sealing washers, tighten to 28 Nm (21 lbf ft).

36

A388140

38

Apply a bead of JCB Multigasket to the mating face of the gearbox cover as shown at

A

. Refit the torque converter housing. Apply JCB Threadlocker and Sealer to the 12 bolts and tighten to 56 Nm (42 lbf ft).

A

A388020

38

221260

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

112 — 12

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 12

Assembly (cont’d)

39

Fit torque converter pressure relief valve assembly

39a

;

Fit the valve ball and spring. Ensure that larger diameter of spring is located securely over the spigot on the plug.

Use a new sealing washer, apply JCB Threadlocker and

Sealer to the plug, then tighten.

Fit the torque converter pressure regulating valve assembly

39b

; Fit the spool and spring. Apply JCB

Threadlocker and Sealer to the plug, then tighten.

40

Using a new gasket mount pressure maintenance valve onto casing. Apply JCB Threadlocker and Sealer to bolts and tighten to 10 Nm (7.4 lbf ft).

Note:

To avoid contamination of sealant printed on gasket face keep in protective wrapper until needed.

41

Assemble pressure maintenance valve spool and spring into adaptor block. Apply JCB Threadlocker and Sealer to plug, fit and tighten.

Do not overtighten

as damage to the aluminium housing could result.

41

44

39b

39a

42

Fit new ‘O’ rings around ports on mating face of solenoid valve. Mount solenoid valve onto pressure maintenance valve, ensuring that port ‘P’ aligns with metering orifice in the pressure maintenance valve body. Apply JCB Threadlocker and Sealer to capscrews and tighten to 5Nm (3.7 lbf ft).

43

Fit the 4 wheel drive solenoid valve. Fit the hydraulic pipe

43a

.

A387980

43a

43

42

9803/3280

Purchased from www.WorkshopManuals.co.uk

A388260

Issue 1

Section F

112 — 13

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 13

*

Assembly (cont’d)

44

If the gear lever turret assembly has been dismantled, apply grease liberally to the working surfaces before assembling. Assembly is the reverse of the procedure detailed in

Gearbox — Dismantling

, Step 1, but note the following:

a

Be sure to locate the slots in the levers

A

with the pegs

B

in the housing

E

.

b

After fitting spring

C

, rotate it so that the end of the bottom coil butts with the the spigot

D

in the housing

E

.

B

A

B

D

E

C

A

A397010

45

Locate a new gasket (not shown) on the casing followed by the gear lever turret baffle plate. Make sure the plate is the correct way round.

45

A388270

46

Locate a second gasket and then fit the turret assembly.

Apply JCB Threadlocker and Sealer to mounting bolts and tighten to 56 Nm (42 lbf ft). Check for gear selection.

46

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

112 — 14

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

112 — 14

Assembly (cont’d)

Note:

It is recommended that a 75 micron (0.075mm) service suction strainer (892/00970) is fitted to clean the system after a major overhaul.

Remove the service strainer and fit a production strainer after the first 100 hours operation. Renew the oil.

47

Using a new gasket, install suction strainer. Apply JCB

Threadlocker and Sealer to bolts and tighten to 10 Nm

(7 lbf ft).

48

Fit a new filter:

a

Smear seal with transmission oil.

b

Screw the filter on until it just contacts the filter head.

c

Turn the filter at least another 3/4 of a turn.

49

Install dipstick/oil filler tube (not shown) as follows:

a

Fit nut to tube followed by seal.

b

Insert tube fully down bore in casing. Engage nut and tighten down loosely onto seal.

c

Tighten nut fully after tube has been correctly phased.

See

2/4 Wheel Drive Clutch

for hydraulic 4WD dismantling and assembly procedures.

47

48

50

Fit a new sealing ring

50a

to the pump drive shaft. Insert the pump drive shaft followed by bearing

50b

and circlip

50c

.

Note:

The main hydraulic pump may be fitted at this stage, or, after the gearbox has been refitted to the machine.

50

50a

50b

50c

A388040

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

113 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

113 — 1

Reverser Unit — Dismantling

1

Carefully remove piston ring seals.

Note:

If the piston ring seals are excessively worn then check for burrs or damage on the shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.

1

S232720

*

2

Remove the taper bearing using pullers.

2

S232720

*

3

Remove the thrust bearing and thrust washers.

*

4

Withdraw the gear and splined hub assembly

4

with the needle roller bearing and spacer. Note the location of the spacer to ensure it is returned to its original position on re-assembly.

4

3

*

5

Remove the thrust bearing and thrust washers.

6

Remove the clutch friction/counter plates retaining circlip.

7

Remove pressure (end) plate.

6

7

5

9803/3280

Purchased from www.WorkshopManuals.co.uk

S407220

S407250

Issue 2*

Section F

113 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

113 — 2

Reverser Unit — Dismantling (cont’d)

8

Remove the clutch friction/counter plates. Keep them together in sets, DO NOT mix the plates with those from other clutches.

9

Remove last counter plate.

*

10

Remove disc spring.

8

9

10

S232741

11

Position clutch assembly in press to compress piston spring then remove circlip.

12

Lift off spring retaining plate.

*

13

Remove spring and oil baffle.

11

12

13

S145000

S407190

14

Knock the clutch shaft on a piece of aluminimum (or wood) to remove the piston.

Note:

If the piston does not loosen when the clutch shaft is knocked on aluminimum, then hand pump air down the shaft oil inlet hole.

S145010

*

15

Remove and discard piston and shaft ‘O’ rings.

*

16

Repeat steps

2

to

15

to dismantle the opposite clutch.

Note that a spacer is not fitted on the opposite

(Forward) clutch. Refer to step 4.

15

S407200

Issue 2* 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

113 — 3

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

113 — 3

Reverser Unit — Assembly

1

Fit new ‘O’ rings onto the piston and shaft, lubricate with oil then press piston fully into bore of clutch housing.

1

S407200

*

2

Install the oil baffle and piston spring, make sure the spring seats in the piston.

3

Fit the spring retaining plate.

4

Compress spring and secure with circlip.

4

3

2

S145000

S407190

5

Fit the disc spring assembly. Fit the assembly so that the outer diameter curves away from the clutch piston.

6

Firstly, fit one counter plate.

7

Fit one friction plate followed by one steel counter plate.

8

Continue fitting alternate friction and plain steel plates, finishing with a friction plate.

7

6

5

10

A

10

9

S232741

9

Fit the pressure (end) plate. Make sure that the chamfered face is fitted facing the clutch pack as shown at

A

. Make sure that the prongs on the pressure plate DO NOT locate in the large grooves in the hub (the ones with drilled holes).

*

10

Fit the clutch friction/counter plates retaining circlip.

Using an air line, blow air down the shaft oil inlet hole and check the piston and clutch pack is free to operate smoothly.

9

9803/3280

Purchased from www.WorkshopManuals.co.uk

S217580

A402700

Issue 3*

Section F

113 — 4

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

113 — 4

*

Reverser Unit — Assembly (cont’d)

11

Using a dial test indicator as shown, measure the end float of the pressure (end) plate, which should be 3.2 to

4.4 mm (0.126 to 0.173 in). If necessary, fit shim between the retaining circlip and pressure (end) plate to correct end float inaccuracies.

S217590

12

Fit the thrust bearing and thrust washers.

12

S407240

13

Fit gear and splined hub assembly.

Note:

Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver).

*

14

Fit the spacer followed by the needle roller bearing.

*

Note:

Ensure that the spacer is fitted first.

*

15

Fit the thrust bearing and thrust washers.

15

14

13

16

Smear the clutch end bearing with JCB HP Grease and press the bearing onto shaft.

*

17

Fit piston ring seals, refer to

Piston Ring Seals — Fitting

Procedure

.

*

18

Repeat steps

1

to

16

for the opposite clutch. Note that a spacer is not fitted on the opposite (Forward) clutch.

Refer to step 14.

16

17

9803/3280

Purchased from www.WorkshopManuals.co.uk

S407220

S232720

Issue 2*

Section F

114 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON)

Section F

114 — 1

Y

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

114 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

114 — 2

Hydraulic 2/4 Wheel Drive Unit

(4WD Pressure ON)

Dismantling

Note:

To aid working on this item, use the output yoke as a stand.

Before dismantling the unit drain the gearbox oil.

Assembly

If only the clutch pack has been removed, begin at step 4.

*

1

Grease the shaft, fit new ‘O’ rings

17

and

18

then locate piston

16

over the shaft and into the housing.

1

Hold the yoke

E

using service tool 892/00812 and undo bolt

F

. Remove the yoke. Carefully remove and discard oil seal

M

. Be sure not to damage the seal housing.

2

Locate oil baffle

15A

, spring position the retainer plate

14

15

into the piston and over the spring.

2

Undo bolts

D

. Lift off the 4WD casing

P

. Lift out the

4WD unit from the gearbox.

3

Using a press and adapter

Y

, compress spring

15

and fit circlip

13

.

3

Remove bearing

1

, only if to be renewed.

4

Build up the clutch pack, installing friction plates

11

and counter plates

12

alternately, starting with a counter plate and ending with a friction plate.

4

Remove seal ring

2

. Note, If the piston ring seal is damaged or excessively worn then check for burrs or damage on the shaft groove. If necessary remove burrs with a fine grade abrasion paper and oil.

*

5

Install pressure plate

10

, shim(s)

9

and circlip

8

. Using an air line, blow air down the shaft oil inlet hole and check the piston and clutch pack is free to operate smoothly.

*

5

Using a puller remove the 4WD output gear

5

, together with its bearing

3

, needle roller bearings

6

and thrust washer washers

4

4

. Remove thrust washer and

7

7

. (Note that thrust are not interchangeable).

*

6

Measure the clutch pack end float using two screwdrivers as shown at

B

. End float should be between 1.0 mm and 2.3 mm. Adjust as necessary, by adding or removing shims

9

.

6

Remove circlip

8

and shim(s)

9

if fitted. Retain any shims as a set for assembly.

Note:

If only the clutch pack was to be removed, the job is now complete.

7

Fit thrust washer

7

, 4WD gear

5

, needle roller bearings

6

and thrust washer

4

.

7

Remove pressure plate

10

, the clutch pack friction plates

11

and counter plates

12

.

8

Press bearing

3

squarely onto the shaft to seat on thrust washer

4

, taking care not to exert any force on the housing i.e. rest the unit on the opposite shaft end, not the housing.

8

Using a suitable press and an adapter similar to

Y

, compress spring

15

and remove circlip

13

.

9

Fit new seal

2

.

9

Remove spring retainer plate

14

, spring

15

and oil baffle

15A

.

10

If required, press a new bearing

1

into position, taking care not to exert any force on the housing (see Step 8).

10

Withdraw piston

16

then remove and discard ‘O’ rings

17

and

18

.

11

Fit the 2/4WD unit to the gearbox.

Note:

The piston housing cannot be separated from the shaft, as on the other types of 2/4WD units.

*

12

Apply a thin bead of JCB Multigasket to the 4WD mating face of the gearbox front case. Fit the case

P

, apply JCB Threadlocker and Sealer to bolts

D

and progressively torque tighten to 56 Nm, 46 lbf ft.

Inspection

Carry out a visual inspection of the friction and counter plates.

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

Do not mix old, new and worn plates.

*

13

14

The 4WD clutch and its associated components are manufactured using a ‘setright’ system. Provided that components have been assembled correctly, the shaft end float will be 0.01 to 0.16 mm (0.0004 to 0.006 in).

Rotate the shaft by hand and ensure that it runs smoothly. Pull the shaft up and down to detect any excessive end float. If there is excessive end float or the shaft runts roughly, dismantle the unit and check for correct assembly.

Fit a new oil seal

M

, fit the output yoke

E

, and flanged bolt

F

. Torque tighten the bolt to 395 Nm; 291 lbf ft.

Two different suppliers of the thinner friction plates (1.6 to

1.7 mm, 0.062 to 0.067 in approx) have been used (identify as brown or green), do not mix the different plates in the same clutch pack.

Inspect the mating faces of the gearbox and 4WD casings for damage.

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section F

115 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

115 — 1

Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

115 — 2

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

115 — 2

Hydraulic 2/4 Wheel Drive Unit

(4WD Spring ON)

Dismantling and Assembly

Note:

Before dismantling the unit drain the gearbox oil.

Dismantling

1

Hold the yoke

E

using service tool 892/00812 and undo bolt

F

. Remove the yoke. Carefully remove and discard oil seal

M

. Be sure not to damage the seal housing.

2

Undo bolts

D

. Lift off the 4WD casing

P

. Lift out the

4WD unit from the gearbox.

3

Remove bearing

1

, only if to be renewed.

4

Remove seal ring

2

. Note, If the piston ring seal is damaged or excessively worn then check for burrs or damage on the shaft groove. If necessary remove burrs with a fine grade abrasion paper and oil.

5

Pull off the 4WD output gear

5,

together with its bearing

3

, needle roller bearing

6

and thrust washer

4

.

6

Using a suitable press, compress disc springs

8A

,

8B

and remove the circlip

7

.

C AU TI ON :

There is ap p ro x im at ely 26700N (6000lb f ) clamping force acting on the springs.

7

Remove disc springs

8A, 8B,

pressure plate

9,

shim(s)

10

(keep the shim(s) separate from the counter plates), and clutch pack friction plates and counter plates

11.

8

Remove t he c lut c h d rum ret aining c irc lip

12

and support washer

13.

9

Remove clutch drum

14

and actuating sleeve

15

.

10

Remove disc spring

16.

11

Remove the piston

17

and its spring steel ring

18.

12

Remove and discard piston O-rings

19

and

20.

13

Remove the piston housing

21

only if necessary, the housing is a press fit on shaft

22.

Inspection

Carry out a visual inspection of the friction and counter plates.

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

Do not mix old, new and worn plates.

Two different suppliers of the thinner friction plates (1.6 to

1.7 mm, 0.062 to 0.067 in approx) have been used (identify as brown or green), do not mix the different plates in the same clutch pack.

Assembly

Note:

Use the pressure test adaptor and clamp assembly

(see

Service tools

) to ‘bench test’ the clutch. Bench testing will ensure the clutch operates correctly prior to — assembling and installing in the machine. Refer to

Hydraulic 2/4 Wheel

Drive Unit

,

Pressure Testing the 2/4 WD Clutch

.

1

Grease the shaft

22

then fit the piston housing

21

by pressing the shaft squarely into the housing (make sure the housing is securely supported on the centre boss).

2

Fit new O-rings

19

and

20

to piston

17,

locate the piston into housing

21.

Fit spring steel ring

18

ensuring that it seats firmly in its groove.

3

Place the disc spring

16

into the housing

21.

4

Position the actuating sleeve

15

onto the disc spring

16.

5

Install the clutch drum

14

in the housing. Fit support washer

13

and drum securing circlip

12.

6

Build up the clutch pack

11,

installing friction plates and counter plates alternately, starting with a counterplate and finishing with a friction plate.

7

Install shim(s)

10

and pressure plate

9

.

8

Use the output gear

5

to align the clutch plate splines.

Ensure that all the plates are engaged with the gear shaft splines. Rotate the output gear back and forth to create maximum backlash then withdraw the gear taking care not to disturb the pack.

9

Place the first two disc springs

8B

with their convex sides uppermost, onto the clutch pack. (There are four disc springs, which are identical). Place the other two disc springs

8A,

with their convex sides down, onto the first two — refer to inset

A

.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

115 — 3

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

115 — 3

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

115 — 4

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

115 — 4

Hydraulic 2/4 Wheel Drive Unit

(4WD Spring ON)

Assembly (continued)

10

Using a suitable press, compress the disc springs

8A

and

8B,

fit circlip

7

.

11

Use levers to remove free play, as shown at

B

. Measure the gap between pressure plate

9

and actuating sleeve

15.

The gap should be 0.75 — 1.5 mm; 0.030 — 0.059

inches. If necessary fit new shim

10

to achieve the correct gap. (Shim

10

can be a combination of a single counter plate, shim (thinner than the counter plate) or both counter plate and shim). Check that the clutch pack splines are still aligned — see step 8.

12

Install the 4WD output gear

5

and its needle roller bearing

6.

13

Install thrust washer

4

and bearing

3

.

14

Fit sealing ring

2

and bearing

1

.

15

Fit the 2/4WD unit to the gearbox.

*

16

Apply a thin bead of JCB Multigasket to the 4WD mating face of the gearbox front case. Fit the case

P

, apply JCB Threadlocker and Sealer to bolts

D

and progressively torque tighten to 56 Nm, 46 lbf ft.

*

17

The 4WD clutch and its associated components are manufactured using a ‘setright’ system. Provided that components have been assembled correctly, the shaft end float will be 0.01 to 0.16 mm (0.0004 to 0.006 in).

Rotate the shaft by hand and ensure that it runs smoothly. Pull the shaft up and down to detect any excessive end float. If there is excessive end float or the shaft runs roughly, dismantle the unit and check for correct assembly.

18

Fit a new oil seal

M

, fit the output yoke

E

, and flanged bolt

F

. Torque tighten the bolt to 395 Nm; 291 lbf ft.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

116 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Gearbox

Section F

116 — 1

Pressure Testing the 2/4WD Clutch

1

Assemble the 2/4 wheel drive clutch, as described in

‘Assembly’.

2

Check the clutch pack end float and adjust as required

(see

Assembly

).

3

Using special tool 993/59300, insert the adaptor

A

into the oil gallery in the end of the 2/4 wheel drive clutch shaft as shown. Hold the adaptor in position with clamp

B

.

4

Use a hand pump to pressurise the clutch assembly until gear, item

5

can be turned by hand. Note the pressure gauge reading — DO NOT EXCEED 200 lb/in 2

(13.8 bar).

5

If the pressure gauge reading is between 125 — 135 lb f/ in 2 (8.6 — 9.3 b ar) t hen t he c lut c h is op erat ing correctly and can be fitted in the transmission.

6

If however the pressure gauge reading is above 135 lbf/in 2 (9.3 bar) then check the clutch for assembly defects, especially the clutch pack end float (the shim may not b e t o t he c orrec t t hic kness). — t est aft er checking for (and rectifying) assembly defects.

A

B

9803/3280

S185720

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

117 — 1

www.WorkshopManuals.co.uk

Transmission

Synchro Shuttle Transmission

Section F

117 — 1

Polytetrafluoroethylene (PTFE) Piston Ring Seals — Fitting Procedure

1

Wind the PTFE piston ring seal around your finger as shown, so that the seal forms a ‘coil’.

157250

2

Smear the seal with grease and then fit the seal to the shaft.

Make sure that the seal sits below or flush with the outer diameter of the shaft. If necessary, use finger pressure as shown to make the seal flush with the shaft.

CAUTION:

If the seal is not set below or flush with the outer diameter of the shaft, then the seal will ‘cut’ when the shaft is fitted to its mating component.

157260

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

120 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

120 — 1

Removal and Replacement c

N

R

M d

J

T

R

K

L

P

S

H

H c d

Y

Z a b a

D b

X

F

G

G

E

B

A401320

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

120 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

120 — 2

Removal and Replacement (cont’d)

IMPORTANT: The gearbox is heavy. Unless it is safely supported during removal and replacement it could fall and cause injury. Make sure that you have access to suitable jacks and a gearbox locating ‘cradle’ before attempting to remove the gearbox.

!

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.

GEN 1-1

Removal

1

Park the machine on firm level ground. The gearbox is heavy. If the ground is soft or uneven it will not be possible to remove the gearbox safely.

2

Loosen the right side rear wheel nuts. Rest the shovel on the ground and lower the stabilisers to raise the rear of the machine. Check dimension

X

which must be at least 800 mm. This will allow the gearbox to be pulled clear. Block/support the machine.

Note:

On sideshift machines, suitable lengths of steel channel can be used as safety struts between the stabiliser feet and chassis, one at each stabiliser.

3

Remove the right hand side rear wheel.

4

Remove the bonnet — see Section 3,

Routine

Maintenance

.

5

Remove the rear axle propshaft — see

Propshafts

.

6

Disconnect the front axle driveshaft bolts

B

(use tool

892/00822).

7

Drain the hydraulic tank and remove the main hydraulic pump (see Section E,

Service Procedures and Main

Hydraulic Pump

). Tie the suction hose up clear of the gearbox.

8

Drain the gearbox oil, see Section 3,

Routine

Maintenance

.

9

Remove the access bung/plate at the bottom of the torque converter housing. Through the access hole, loosen and remove the torque converter to engine flywheel retaining bolts

D

.

10

At a later stage the gearbox and engine assembly is tilted to allow access to fixing bolts. To prevent damage as the engine is tilted components must have their fixings removed as follows:

a

Fuel sediment bowl assembly

E

(2 bolts).

b

Exhaust stack fixing bracket

F

(2 bolts).

d

Radiator fan cowl

G

(4 bolts).

It is not necessary to remove these components, only release them from their fixings.

11

Support the gearbox using a suitable trolley jack and cradle. The gearbox must be securely located on the cradle as shown at

Y

.

12

Make sure that the weight of the gearbox is supported by the trolley jack and then remove the gearbox mounting bolts

H

.

13

Using the trolley jack, lower the gearbox and engine to gain access to the top torque converter housing to engine block retaining bolts

J

. Put a support under the engine as shown at

Z

to prevent it from dropping when the gearbox is removed.

14

Undo the four bolts

J

at the top of the torque converter housing. Note that the two outer most bolts have nuts instead of screwing into the engine block. Also note the position of the electrical earth straps.

15

Pull off the breather tube

K

. Undo the gearbox dipstick fixing nut

L

and then remove the dipstick tube.

16

Label and then uncouple the solenoid control valve electrical connectors

M

, oil pressure sender

N

and temperature sender

P

(if fitted). Uncouple the electrical connector at the speed sensor

S

.

17

Disconnect the gearbox oil cooler hoses

R

.

18

Remove the flywheel housing to engine bolts

T.

19

Manoeuvre the gearbox with the torque convertor clear of the engine housing.

20

Lower the trolley jack and pull the gearbox and torque convertor clear of the machine.

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

120 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

120 — 3

Removal and Replacement (cont’d) c

R

M d

J

T

N

K

L

P

S

H

H c d

Y

Z a b a

D b

X

F

G

G

E

B

A401320

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

120 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

120 — 4

Removal and Replacement (cont’d)

Replacement

Replacement is a reversal of the removal procedure but note the following:

1

Before replacing the gearbox remove circlip

5

and withdraw the pump driveshaft

6

together with its bearing

7

approximately 50 mm (2.0 in). The shaft can then be engaged after the gearbox has been fitted, making replacing the gearbox easier. Remember to engage the pump drive shaft, refit the bearing and circlip after the gearbox has been fitted.

2

Set the torque converter as described in

Torque

Converter, Removal and Replacement

.

3 Align the Torque Converter

It is vitally important that the torque converter is fitted at the gearbox and engine flywheel correctly

.

Failure to locate the converter correctly will result in damage to the gearbox oil pump on engine start up.

Proceed as follows:

Make sure that the torque converter drive dogs

1

are correctly engaged with the pump

2

on the gearbox.

Temporarily tie the converter onto the gearbox. Use wire tied at a drive plate bolt hole to a convenient point on the outside of the gearbox.

Take note of the flywheel and drive plate fixing hole phasing. The heads of the bolts

3

will foul the flywheel

4

if phasing is incorrect.

Before bolting the torque converter housing to the engine make sure the mating faces are fully together

(DO NOT USE FORCE). The drive plate

8

should also be mated close to the flywheel. Do not force the components together with the fixing bolts.

Make sure that the torque converter is free to rotate slightly within the clearance of the location bolt holes. If you cannot rotate the converter it is trapped either by bolt heads

3

or by incorrectly located pump drive dogs.Make sure that all is well before tightening the bolts.

4

Fill the gearbox with the specified amount and type of oil (see

Section 3, Routine Maintenance

). Leave hose

N

off until the filling operation is complete. After filling refit hose

N

.

Torque Settings

Item

B

D

H

J,T

Nm

79

44

237

98

kgf m lbf ft

8 58

4.5

24

10

32

175

72

1

5

2

6

7

4

8

3

A396460

A396900

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

125 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 1

1a

1a

A395250

1b

1c

1e

1d

A395260

2b

2a

3b

9803/3280

Purchased from www.WorkshopManuals.co.uk

3a

A395540

Issue 1

Section F

125 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 2

Dismantling

N ot e :

The Dism ant ling , Insp ec t io n and Assem b ly procedures in this manual illustrate and describe the 6×4 gearbox. Procedures for the 4×4 version of the gearbox are indentical in most respects. Where there are differences procedures are identified under the heading ‘

4×4 Gearbox

’.

With the gearbox removed from the machine, place suitable wooden blocks to securely support the assembly.

Cleanliness is of the utmost importance when servicing the gearbox. All precautions to prevent any ingress of dirt, grit etc. must be taken. To this end wash the exterior of the gearbox assembly as follows;

Make sure that all open ports and orifices are effectively plugged. Remove any deposits of dirt, grit and oil from the outer casings using a suitable degreaser and water. Dry the casings.

1 Remove the Main Hydraulic Pump and Driveshaft a

If t he main hyd raulic p ump has not alread y b een removed proceed as follows. Support the pump, undo the 2 bolts

1a

. Draw the pump away from the gearbox, disengaging the drive shaft. Lift the pump clear.

b

Rem o ve t he c irc lip

1b

f o llo w ed b y b earing

1c

.

Withdraw the driveshaft

1d

. Remove the sealing ring

1e

.

2 Remove the Solenoid Control Valve Block a

Undo the 8 socket head cap screws

2a

and lift off the valve block assembly

2b

. Do not use a screwdriver to lever the block, the sealing faces will be damaged. If the block is difficult to remove, lightly tap the manifold block with a soft faced hammer.

Note:

Some gearboxes are fitted with a valve block subbase plate. Be sure to retrieve the plate. The plate is thin, make sure it is not damaged when removing. Take care not to damage the surfaces of the plate.

b

Remove and discard the valve block sealing gasket.

The gasket may disintegrate on removal, make sure all traces are removed and discarded. Gearboxes fitted with a sub-base plate have two gaskets, one each side of the plate.

3 Remove the Layshaft Cover

Note:

Unless the casings are to be renewed, or the gearbox oil has been contaminated it is not necessary to remove the cover.

a

Undo the 6 bolts

3a

and lift off the cover

3b

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

125 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 3

A

5b

5a

5c

5d

b

B

A396090

4a

4a

5b

4a

6c

A395230

6b

6g

6a

6b

6d

4b

6f

A395240

9803/3280

A395330

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

125 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 4

Dismantling (cont’d)

Using suitable lifting equipment locate the gearbox in a work cradle (892/01082) as shown at

A

. Clamp the gearbox in position at the 3 clamping points on the rear casing as shown at

B

. DO NOT ATTEMPT TO DISMANTLE THE

GEARBOX FURTHER UNLESS IT IS SAFELY LOCATED IN A

SUITABLE WORK CRADLE.

4 Remove the Torque Converter Housing

*

a

Undo the bolts

4a

† . Note that 2 bolts are located on the outside of the housing just above the oil filter mounting.

Lift off the housing. Retrieve the sealing ‘O’ ring

4b

.

† Early gearboxes feature a total of 18 bolts while late gearboxes have 23 bolts

5 Remove the Gearbox Hydraulic Pump a

Undo the 4 fixing bolts

5a

and lift the pump assembly

5b

off the input shaft. Retrieve the 4 sealing washers

5c

and pump sealing ring

5d

.

Note:

A pump which is worn or damaged may have caused further damage to the gearbox. Dismantle and inspect the gearbox fully. For details of dismantling and inspecting the pump, see

Powershift Gearbox — Inspection

.

6 Remove the 4WD Clutch Assembly a

Using service tool 892/00812 hold the output yoke

6a

and at the same time undo the bolt

6b

. The bolt is very tight, the help of an assistant will be required.

b

Remove the thick washer

6g

and yoke

6a

. Undo the 8 bolts

6c

and lift off the cover

6d

, be sure to retrieve the bearing outer cup from inside the cover. Remove the output shaft oil seal

6b

. Take care not to damage the seal housing.

c

Lift the clutch and shaft assembly

6f

from the housing.

Retrieve the inner bearing outer cup from the casing.

For 4WD clutch dismantling and assembly procedure see

4WD Clutch — Dismantling and Assembly

in this section.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

125 — 5

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 5

7a

7b

7c

9f

9g

8a

8b

7d

8c

9c

9h

10b

A396120

9b

9a

10c

10a

10e

10d

10f

A395210

10g

10h

9803/3280

9e

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

125 — 6

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 6

Dismantling (cont’d)

7 Remove the Torque Converter Relief Valve

*

a

Undo the plug

7a

and remove the sealing washer

7b

, spring

7c

and poppet

7d

. Note that some gearboxes are fitted with a ball instead of a poppet.

8 Remove the Pressure Maintenance Valve a

Undo the plug

8a

, remove spring

8b

and valve spool

8c

.

9 Separate the Front and Rear Casings a

Remove the 4WD clutch oil pipe

9a

.

b

Undo the 17 casing bolts

9b

.

c

Using suitable lifting equipment carefully lift off the front case

9c

. Be sure to retrieve all the shaft bearing outer cups. The cups may be left on the bearings, or inside the front case. Keep the cups with their associated bearings.

d

Remove and discard the 3 sealing ‘O’ rings

9e

from the front case.

Note:

The 3 oil transfer pipes

9f, 9g

and

9h

located inside the front case need not be removed unless they are damaged, or the gearbox oil has been contaminated. If they are to be removed see

Powershift Gearbox — Inspection

.

4×4 Gearbox:

pipe

9h

not fitted.

10 Remove the Clutch/Shaft Assemblies a

Carefully lift out the clutch/shaft assemblies in the following order:

10a

— 6 speed clutch shaft (not fitted to

4×4 Gearbox

)

10b

— Reverse clutch unit

10c

— Forward/Input clutch shaft

10d

— Layshaft clutch

10e

— Mainshaft clutch

b

Retrieve the bearing outer cups from the rear case

10f

and centre of the transfer gear

10g

. Note that the layshaft bearing cup

10h

can not be removed until the transfer gear/output shaft has been removed, see step

11. Keep the cups together with their associated bearings.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

125 — 7

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 7

11c

11d

11b

11r

11p

11m

11g

11h

11j

11k

9803/3280

11f

11e

Purchased from www.WorkshopManuals.co.uk

A395280

11a

Issue 1

Section F

125 — 8

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

125 — 8

Dismantling (cont’d)

11 Remove the Transfer Gear b

Using service tool 892/00812 hold the output yoke

11b

and at the same time undo the bolt

11c

. The bolt is very tight, the help of an assistant will be required. Remove the bolt, thick washer

11d

followed by the yoke.

c

Remove and discard the oil seal

11g

. Take care not to damage the seal housing.

d

Sup p o rt t he t ransf er g ear/ shaf t assem b ly

11a

.

Wit hd raw t he g ear f ro m insid e t he c asing . The assembly will lift away complete with the inner taper roller bearing

11e

and spacer

11f

.

f e

Remove the outer taper roller bearing

11h

.

Remove circlip cup

11k

.

11j

followed by bearing double outer

Note:

The inner and outer taper roller bearing assembly

(comprising double outer cup

11k,

inner bearing

11e

, spacer

11f

and outer bearing

11h

) is a matched set. Keep all the c o m p o nent s t o g et her in t heir o rig inal relat io nship s.

Components from another set are not interchangeable. If any components are worn or damaged the whole assembly must be renewed as a complete matched set.

g

Retrieve the layshaft bearing outer cup

11r

from the rear casing.

h

If the speed sensor

11m

is to be removed, undo bolt

11p

and withdraw the sensor together with its sealing

‘O’ ring.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

126 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

126 — 1

Inspection

4b

4a

A395290

5a

5b

5c

A395210

5e

5f

9803/3280

A395110

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

126 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

126 — 2

Inspection

Before assembling the gearbox, make sure that a thorough inspection of all components is carried out. Remember that although a failed component may be easy to identify, the cause of that failure may be less easy to trace. It is also possible that a failed component may have caused damage to other areas of the gearbox.

b

If the existing pump is to be re-installed proceed as follows;

Undo the security screw

4a

and separate the pump body. Carefully inspect the gear teeth, white metal bearing and gear/body mating faces for signs of wear and damage, (If either is evident, the pump must be renewed).

Carefully remove and discard the oil seal

4b

. Take care not to damage the seal housing. Fit a new seal and then re-assemble the pump.

1 Cleaning a

Carefully remove all traces of gasket or gasket compound from the following components:

*

Note:

When removing gasket compound use a gasket removal product such as Loctite Chisel. Take care not to damage the mating faces. Clean the faces with a fine carborundum paper. Use a solvent cleaner and a clean cloth to finally remove all traces of oil or debris.

c

Make sure that pump the mating face on the gearbox

5

front cover is clean and free from surface damage.

Oil Transfer Pipes

Front and rear casing mating faces.

Front casing and torque converter housing mating faces.

Main hydraulic pump and rear casing mating faces.

Solenoid control valve manifold and casing mating faces.

4WD casing mating faces.

Layshaft cover and rear casing mating faces.

Pressure maintenance valve bore (front case)

The front case incorporates oil transfer pipes

5a

,

5b

and

5c

.

If the pipes are damaged or if the gearbox has been contaminated, the pipes must be removed for cleaning or renewal.

4×4 Gearbox:

pipe

5c

not fitted.

a

Using a ‘crows foot’ type spanner and a ratchet wrench undo the pipes from the adaptors in the casing. Unless pipes are being transferred to a new casing it will not be necessary to remove the pipe adaptors.

6×4 Gearbox Only:

If the adaptors are to be removed, adaptor

5e

must be removed last.

b

Clean the inside of the casings using a suitable degreasing agent.

2 General Inspection a

Carefully inspect all gears, bearings and shafts for signs of excessive wear or damage. If wear or damage is evident, components must be renewed.

b

If the adaptors have been removed make sure that the sealing rings are renewed and fitted correctly.

6×4 Gearbox Only:

Position the lock nut

5f

on adaptor

5e

as shown and then fit the adaptor to the case.

Screw in until the locking nut reaches the case. Do not tighten the locking nut down at this stage.

All Gearboxes:

Fit the adaptors. Torque tighten to

70 Nm.

Note:

The transfer gear shaft inner, outer bearing and spacer assembly is a matched set. If any of the components are damaged or worn the complete assembly must be renewed. Components are not interchangeable between bearing sets.

b

Make sure that all oil way cross drillings are clear and free from debris. Blocked oil ways are a common cause of bearing failure. If necessary use an air line to blow through the oil ways.

c

Make sure the pipes are clear and free from debris before refitting. Loosly fit the pipes

5a

and

5b

. Make sure they are fitted at the correct adaptors as shown.

6×4 Gearbox Only:

Loosly fit the pipe

5c,

rotate adaptor

5e

so that the pipe is not strained. Torque tighten down the lock nut

5f

to 70 Nm.

All Gearboxes:

Torque tighten the pipes to 30 Nm.

6 Casings

3 Clutch Units a

If clutch failure is suspected see the relevant clutch dismantling and assembly procedure in this section.

If the gearbox casings are to be renewed, be sure to fit blanking plugs and adapters as required. Inspect the original casings and identify the blanking plug and adapter positions.

Transfer the plugs and adapters to the new casings. Apply

JCB Threadlocker and Sealer to the threads.

4 Gearbox Hydraulic Pump a

If tests have shown the pump performance to be unacceptable, the pump must be renewed as a complete unit.

Note that new plugs may be supplied with a sealant ‘patch’, in which case sealant need not be applied.

*

Note:

Early gearboxes feature a ‘18 bolt fix’ torque converter housing. It is strongly recommended that a new ‘23 bolt fix’ housing and matching front case is fitted on assembly of the gearbox. A compatible torque converter relief valve will also be required.

9803/3280 Issue 3*

Purchased from www.WorkshopManuals.co.uk

Section F

127 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 1

1k

B

1j

1h

1b

1a

1b

1a

11f

1g

1f

1b

1a

D

A396070

C

9803/3280

1e

1c

Purchased from www.WorkshopManuals.co.uk

A395280

1d

Issue 1

Section F

127 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 2

Assembly

Using suitable lifting equipment locate the gearbox rear casing in a work cradle. Clamp the casing in position at the 3 clamping points as shown at

A

.

DO NOT ATTEMPT TO ASSEMBLE THE GEARBOX UNLESS

IT IS SAFELY LOCATED IN A SUITABLE WORK CRADLE.

Where ‘oil’ is referred to, use new, clean transmission oil of the correct specification for the gearbox. See

Section 3,

Lubricants and Capacities

.

1

Assemble the Transfer Gear/Output Shaft

Note 1:

Before fitting the transfer gear/output shaft assembly

1d

, fit the layshaft outer bearing cup to the casing (shown at

E

).

Position the casing as shown at

D

.

Note 2:

The inner and outer taper roller bearing assembly

(comprising double outer cup

1a,

inner bearing

1c

, spacer

1e

and outer bearing

1f

) is a matched set. Keep all the components together in their original relationships.

Components from another set are not interchangeable. If any components are worn or damaged the whole assembly must be renewed as a complete matched set.

a

Make sure that you have fitted the layshaft outer bearing cup, see

Note 1

above. Fit the bearing double outer cup

1a

into the casing. Note the correct way up of circlip

1b

, with the chamfer uppermost. Make sure that the circlip locates fully in its groove as shown at

B

. The tangs of the circlip must not overhang the inner diameter of the bearing cup 1

a

. An incorrectly located circlip can foul and damage the outer bearing.

b

Push the inner bearing

1c

onto the transfer gear/shaft

1d

followed by spacer

1e

.

d

Locate the transfer gear assembly in the casing from inside. Using service tool 892/01083 retain the gear in position (shown at

C

). If the gear is not held in position the bearings may be damaged during assembly.

c

Using service tool 892/01084 push on the outer bearing

1f

. Using service tool 892/01085 fit a new oil seal

1g

.

Make sure the seal is pushed square to the housing.

f e

Fit yoke

1h

followed by thick washer

1j

and bolt

1k

. Hold the yoke using service tool 892/00812 and torque tighten the bolt to 400 Nm (295 lbf ft).

If applicable fit the speed sensor

11f

. Make sure that the sealing ‘O’ ring is correctly located and then torque tighten the bolt to 28Nm (20 lbf ft).

2

Checking Transfer Gear/Output Shaft

Assembly End Float

The transfer gear/output shaft and its associated components are manufactured using a ‘Setright’ system.

Measure the rolling torque at the yoke

1h

. Provided components have been assembled correctly the torque will be between 0.6 and 2.2 Nm (0.5 and 1.6 lbf ft).

A

A395580

A396090

E

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

127 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 3

A

3e

3e

3f

3g

3c

3d

A396050

3a

3b

4a

A395060

B

A395620

4b

4b

9803/3280

4c

A395210

Purchased from www.WorkshopManuals.co.uk

A335160

Issue 1

Section F

127 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 4

Assembly (cont’d)

3 Fit the Clutch/Shaft Assemblies a

Fit the bearing outer cups at their correct locations in the rear case

3a

and centre of the transfer gear

3b

.

b

Carefully fit the clutch/shaft assemblies in the following order:

Note:

When fitting the layshaft clutch take care not to damage the rear bearing on the transfer gear teeth.

Note:

Before fitting the input clutch shaft make sure that the

4 sealing rings (shown at

A

) are in good condition and lubricated with oil.

3c

— Mainshaft clutch

3d

— Layshaft clutch

3e

— Forward/Input clutch shaft

3f

— Reverse clutch unit

3g

— 6 speed clutch shaft (not fitted to

4×4 Gearbox

)

c

Make sure that the sealing rings on the ends of the clutch shafts

3c

,

3d

,

3f

and

3g

are in good condition and lubricated with oil.

4×4 Gearbox:

clutch

3g

(6 speed) not fitted.

4 Assemble the Front and Rear Casings a

Make sure that the 3 off ‘O’ rings

4a

are correctly fitted to the rear case.

b

Apply a thin bead of JCB Multigasket to the rear casing mating face as shown at

B

.

c

Make sure that the shaft bearing outer cups are correctly located in the front case

4b

and then carefully lower the case over the clutch shafts until it mates with the rear case. Do not use excessive force when fitting the case.

d

Fit the 17 casing bolts

4c

and progressively torque tighten to 56 Nm (41 lbf ft).

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

127 — 5

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 5

5e

5b

X

5d

Y

5a

5c

A335160

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

127 — 6

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 6

Assembly (cont’d)

5

Checking the Clutch Shaft End Floats

Provided components are assembled correctly the end float will be within the limits given. Check that the shafts can be rotated by hand (turn the input shaft and output yoke). The shafts should rotate smoothly. The end floats can be checked to confirm correct assembly.

End float for all shafts will be within the range 0.02 mm to

0.16 mm (0.0008 to 0.0063 in).

All shafts except the Input Shaft:

Shaft

5a —

Mainshaft

Shaft

5b —

Reverse clutch unit

Shaft

5c —

Layshaft

Shaft

5d —

6 speed shaft (not fitted to 4×4 gearboxes)

a

Remove the plugs

X

and

Y

from the front casing.

4×4 Gearbox:

plug

Y

not fitted.

b

Fit a bolt to the threaded hole in the end of the shafts.

Pull up on the bolt to detect excessive end float.

Remove the bolt.

c

Apply JCB Threadlocker and Sealer to the plugs

X

and

Y

as applicable. Torque tighten the plugs to 102 Nm

(75 lbf ft).

Input Clutch Shaft: a

Pull on the input shaft

5e

to detect excessive end float.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

127 — 7

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 7

6e

C

7c

6j

6h

6g

6f

6c

B

7c

7b

7a

7b

7a

8c

8b

8a

6b

A395240

6a

A395570

A

Y

Y

Y

9a

9b

X

9c

9d

Y

9803/3280

A405220

Purchased from www.WorkshopManuals.co.uk

A395230

Issue 3*

Section F

127 — 8

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 8

Assembly (cont’d)

6

Fit the 4WD Clutch Assembly

a

Fit the 4WD clutch oil feed pipe

6a

at the casing.

b

Make sure the shaft bearing outer cup is correctly located in the front casing (not shown) and then locate the clutch and shaft assembly

6b

in the the housing.

*

c

Make sure that the front and 4WD casing (

6c

) mating faces are clean and undamaged. Apply a 3 mm bead of

Loctite 509 to the front casing as shown at

A

. Note that the bead is applied near the inner or outer edge of the flange as applicable at positions

Y

. Make sure that the shaft bearing outer cup (not shown) is correctly located inside the 4WD casing and then fit the casing. Fit 8 off bolts

6e

and progressively torque tighten to 56 Nm

Check the 4WD clutch shaft end float:

Provided components are assembled correctly the end float will be within the limits given. Rotate the shaft by hand, it should rotate smoothly.

The end float can be checked to confirm correct assembly.

End float must be within the range 0.01 mm to 0.16 mm

(0.0004 to 0.0063 in).

f d

Fit a bolt to the threaded hole in the end of the shaft. Pull up on the bolt to detect excessive end float.

e

Fit a new oil seal

6f

. Make sure the seal is pushed square to the housing.

Fit the output yoke

6g

, followed by thick washer

6h

and bolt

6j

. Hold the yoke using service tool 892/00812 and at the same time torque tigten the bolt to 400 Nm (295 lbf ft).

7 Fit the Torque Converter Relief Valve

*

Note:

The torque converter relief valve may be of a ball type

(shown at

B

), or poppet type (shown at

C

).

a

Fit the ball or poppet (see note above)

7a

followed by the spring

7b

. Using a new sealing washer fit plug

7c

.

8 Fit the Pressure Maintenance Valve a

Oil the spool

8a

and fit to the casing. Fit spring

8b

. Apply

JCB Threadlocker and Sealer to the plug

8c

. Using a new sealing washer fit plug.

9 Fit the Gearbox Hydraulic Pump a

Make sure that the pump is fitted with a new oil seal

9a

, see

Powershift Gearbox, Inspection, step 4

.

Fit a new sealing ring

9b

. Locate the pump over the input shaft aligning the bolt holes. Apply JCB

Threadlocker and Sealer to bolts

9c

. Fit the bolts together with new sealing washers

9d

. Progressively torque tighten the bolts to 28 Nm (20 lbf ft).

b

Pour some clean, new, oil into the pump at position

X

.

9803/3280 Issue 3*

Purchased from www.WorkshopManuals.co.uk

7

5

2

1

3

10

13

Section F

127 — 9

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 9

A

X

X

X

A396130

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

A402660

11

14

18

17

19

8

6

12

15

9

4

Issue 2*

Section F

127 — 10

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 10

Assembly (cont’d)

10 Fit the Torque Converter Housing — Gearboxes with

18 bolt fix only

*

Important Note:

Only the specified sealant can be used. The machine

MUST NOT

be operated for at least 6 hours after sealant has been applied and the converter housing assembled. This is to allow time for the sealant to cure.

a

Make sure that the front case and torque converter housing (

10a

) mating faces are clean, dry and undamaged. Apply a 3 mm wide bead of Bondloc B574 sealant to the front casing as shown at

A

(pump not shown for clarity). Make sure that sealant is applied between all the port channels as shown. Take extra special care in the area

X

as sealing is critical in these areas. Be sure not to block galleries with sealant. Fit a new ‘O’ ring

10d

to the housing

10a

.

b

Carefully locate the torque converter casing on the front case. Fit new 10.9 grade bolts as follows:

M10 bolts

10b

(15 off). Note that spacers are fitted under bolts at positions 10 and 14.

M8 bolts

10c

. (3 off)

Progressively torque tighten the bolts in the sequence shown. Note that the bolt at position 1 is re-torqued after tightening the bolt at position 15.

Sequence

1 — 9

10

11 — 13

14

15

16

17 — 19

Bolt Position

(shown at

B

)

1 — 9

10

11 — 13

14

15

1 (Re-torque)

17 — 19

Torque

Nm

78

60

78

60

78

78

38 lbf ft

57.5

44.25

57.5

44.25

57.5

57.5

28

10a

10c

10c

10c

10b

10d

A401250

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section F

127 — 11

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 11

A

X

X

X

A404970

B

10a

9

13

17

3

8

6

16

19

12

14

Y

Y

Y

Y

Y

9803/3280

Y

Y

A404980

11

15

7

4

21

20

23

M8 x 45 mm

1

2

5

10

18

22

M8 x 25 mm

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section F

127 — 12

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 12

Assembly (cont’d)

10 Fit the Torque Converter Housing — Gearboxes with

23 bolt fix only

Important Note:

Only the specified sealant can be used. The machine

MUST NOT

be operated for at least 6 hours after sealant has been applied and the converter housing assembled. This is to allow time for the sealant to cure.

a

Make sure that the front case and torque converter housing (

10a

) mating faces are clean, dry and undamaged. Apply a 3 mm wide bead of Loctite 509 sealant to the front casing as shown at

A

(pump not shown for clarity). Make sure that sealant is applied between all the port channels as shown. Take extra special care at positions

X

as sealing is critical in these areas. Be sure not to block galleries with sealant. Fit a new ‘O’ ring

10d

to the housing

10a

.

b

Carefully locate the torque converter casing on the front case. Fit new 10.9 grade bolts (shown at

B

) as follows:

M10 x 35 mm bolts (21 off). Note that on some gearboxes spacers are fitted under bolts at positions

Y

.

M8 x 25 mm bolt at position 22.

M8 x 45 mm bolt at position 23.

Progressively torque tighten the bolts in the sequence shown.

Sequence

1 — 21

22 — 23

Bolt Position

(shown at

B

)

1 — 21

22 — 23

Torque

Nm

78 lbf ft

57.5

35 — 40 26 — 30

10a

10d

A401250

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

127 — 13

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 13

11b

813/10177 A

11a

A390510

13a

9803/3280

12c

12d

12a

12b

13b

A395260

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

127 — 14

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

127 — 14

11 Fit the Solenoid Control Valve Block a

Fit two guide studs at the valve interface on the front case. Locate a new valve block sealing gasket

11a

as shown at

C

. Care is needed as the gasket is thin.

Gearboxes fitted with a sub-base plate have two gaskets, one each side of the plate.

b

Fit the 8 socket head cap screws and washers

11b

. The screws must be progressively torque tightened.

Gradually tighten all the screws to 35 Nm (26 lbf ft).

12 Fit the Main Hydraulic Pump Driveshaft a

Fit a new sealing ring

12a

to the shaft

12b

. Apply clean oil to the sealing ring and fit the shaft inside the gearbox.

b

Apply clean oil to the ball bearing

12c

. Fit the bearing followed by circlip

12d

.

13 Fit the Layshaft Cover a

If applicable fit the layshaft cover

13a

. Make sure the casing mating faces are clean and undamaged. Apply a thin bead of JCB Multigasket to the rear casing and fit the cover. Fit bolts

13b

and progressively torque tighten to 56Nm (41 lbf ft).

Note:

The main machine hydraulic pump can be fitted at this stage. However, it is easier to fit the gearbox to the machine and then fit the pump.

See Section E, Main Hydraulic

Pump, Replacement.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

130 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

130 — 1

PS 760 — Forward/Input & Reverser Clutch — Dismantling

21

22

23

6

10

9

8

11

14

1

2

3

4

5 7

16

17

18

19

16

20

13

15

23

21

20

19

18

17

14

8

12

22

2

3

6

12

14 15

15

13

12

11

24

10

9

25

29

30

28

27

26

16

23

11 29

27

26

A396140

24

9803/3280

17

13

19 21 22

20

10

28

18

30

A396270

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

130 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

130 — 2

PS 760 — Forward/Input & Reverser Clutch — Dismantling

Note:

The illustration shows a reverser shaft assembly for the 6 — speed transmission. The input shaft assembly has some small differences. An explanation of the differences will be given as they occure in the procedure. The input and reverser shaft assemblies for the 6 — speed transmission and the 4 — speed transmission are the same basic construction, except the 4 — speed transmission have fewer friction/counter plates.

11

Lift off spring retaining plate

18

.

12

Remove spring

19

and oil baffle

20

.

13

Turn the assembly over and knock the clutch shaft on a piece of aluminium (or wood) to loosen the piston

21

.

1

Carefully remove piston ring seals

1

. The input shaft does not have piston ring seals fitted at this end of the shaft.

Note:

If the piston does not loosen when the clutch shaft is knocked on aluminium, then hand pump air down the shaft oil inlet hole.

14

Remove the piston

21

. Remove and discard the piston

‘O’ ring

22

and shaft ‘O’ ring

23

.

Note:

If the piston ring seals are excessively worn then check for burrs or damage on the shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.

15

To dismantle the opposite clutch, carefully remove piston ring seal

24

. The input shaft has four piston ring seals fitted at this end of the shaft.

2

Remove the clutch end bearing

2

and gear

3

, using a puller or press.

16

Loosen the clutch end bearing

25

and remove using a puller.

3

Remove the thrust bearing

4

and thin thrust washer

5

.

4

Withdraw the gear and splined hub

6

with the needle roller bearing

7

.

17

Remove thrust bearing

27

and thick and thin thru washers

26

and

28

.

5

Remove thrust bearing

9

and thick and thin thrust washers

8

and

10

.

18

Withdraw the gear and splined hub

29

with the need roller bearing

30

.

19

Repeat steps

5

to

14

to dismantle the clutch assembl

6

Remove the friction/counter plates retaining circlip

11

.

7

Remove pressure end plate

13

and shim

12

, if fitted.

8

Remove the friction plates

14

and counter plates

15

.

Keep them together in sets, DO NOT mix the plates with those from other clutches.

9

Remove disc spring assembly

16

.

10

Position clutch assembly in a suitable press, with a cut away tube compress the piston spring then remove circlip

17

.

17

A401360

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

130 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

130 — 3

PS 760 — Forward/Input & Reverser Clutch — Assembly

21

22

23

6

10

9

8

11

14

1

2

3

4

5 7

16

17

18

19

16

20

13

15

23

21

20

19

18

17

14

8

12

22

15

13

12

11

24

25

10

9

29

30

28

27

26

A396140

2

3

6

12

14 15 16

23

11 29

27

26

24

A

11

13

9803/3280

17

13

19 21 22 20

10

28

18

30

A396270

Purchased from www.WorkshopManuals.co.uk

A402700

Issue 3*

Section F

130 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

130 — 4

PS 760 — Forward/Input & Reverser Clutch — Assembly

Visually inspect the friction and counter plates:

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

DO NOT mix old and new plates, if a plate is damaged/worn fit a complete new set.

Needle roller bearings should slide into position freely, do not bend or distort the cage to fit. If the cage has been distorted fit new bearings.

9

Using a dial test indicator as shown, measure the end float of the pressure end plate

13

, which should be 1.90

to 2.50 mm (0.075 to 0.098 in).

If it is necessary to adjust the end float to bring it within tolerance, there is a choice of fitting a 6.0mm (0.23in) or

6.5mm (0.25in) thick pressure end plate

13

, with either a shim

12

or an extra counter plate

15

between the retaining circlip

11

and pressure end plate

12

.

Use an airline to check the operation of the clutch.

10

Fit thick and thin thrust washers

8

and

10

, and thrust bearing

9

.

11

Carefully align the teeth of the clutch plates using a thin rod (or screwdriver) and fit the gear and splined hub

6

.

Take care when handling disc spring assemblies

16

to avoid marking or damage, which could result in stress cracking. If in doubt fit a new disc spring.

Note:

The piston incorporates a small check valve. Visually inspect the piston to ensure the ball is in place and that the seat is free from contamination. If necessary clean the valve by blowing through with an air line. DO NOT use a wire rod

(or screwdriver) as damage to the valve seat could occur.

1

Fit new ‘O’ rings

23

and

22

. Lubricate the piston

21

with oil and press fully into bore of clutch housing.

2

Fit the oil baffle

20

, piston spring

19

, make sure the spring seats in the piston.

12

Fit needle roller bearing

7

.

13

Fit thrust bearing

4

and thin thrust washer

5

.

14

Smear the clutch end bearing with gearbox oil and press the gear

3

and bearing

2

onto the shaft.

15

Fit piston ring seals

1

, refer to

Piston Ring Seals —

Fitting Procedure

. The input shaft does not have piston ring seals fitted at this end of the shaft.

16

To assemble the opposite clutch repeat steps

1

to

10

.

17

Carefully align the teeth of the clutch plates using a thin rod (or screwdriver) and fit the gear and splined hub

29

.

3

Fit the spring retaining plate

18

.

4

Compress the spring and secure with circlip

17

.

5

Fit the disc spring assembly

16

. Make sure that the disc spring is fitted with the teeth towards the clutch pack.

Make sure the teeth are not aligned with the lubrication slots in the housing.

6

Fit one counter plate

15

, followed by one friction plate

14

. Continue fitting alternate counter and friction plates, finishing with a friction plate.

*

7

Fit the pressure end plate

13

. Make sure that the chamfered face is fitted facing the clutch pack as shown at

A

. Make sure the teeth are not aligned with the lubrication slots in the housing. Do not fit shim

12

at this stage.

8

Fit the clutch friction/counter plates retaining circlip

11

.

18

Fit needle roller bearing

30

.

19

Fit thrust bearing

27

and thick and thin thrust washers

26

and

28

.

20

Smear the clutch end bearing with gearbox oil and press bearing

25

onto the shaft.

21

Fit piston ring seal

24

, refer to

Piston Ring Seals —

Fitting Procedure

. The input shaft has four piston ring seals fitted at this end of the shaft.

S217590

Issue 2* 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section F

131 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

131 — 1

PS760 — Layshaft Clutch — Dismantling

8

8

9

10

9A

11

5

4

6

7

6

1

2

3 17

16

13

14

15

12

18

19

20

21

22

23

24

1

2

6

5

13

14

16

17

24

A396160

12

9803/3280

3

4

7

8

11

15

18

20

19

22

21

23

Purchased from www.WorkshopManuals.co.uk

A396230

Issue 2*

Section F

131 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

131 — 2

PS760 — Layshaft Clutch — Dismantling

Note:

The illustration shows a layshaft assembly for a 6 speed transmission. The layshaft assembly for a 4 — speed transmission has some small differences. An explanation of the differences will be given as they occure in the procedure.

1

Carefully remove piston ring seals

1

.

Note:

If the piston ring seals are excessively worn then check for burrs or damage on shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.

2

Remove taper roller bearing

2

using a suitable puller or press.

3

Remove circlip

3

and withdraw the 4 wheel drive transfer gear

4

. Make a note which way round the gear is fitted for assembly. The 2 wheel drive machines have a spacer fitted instead of a gear.

4

Withdraw the gear and splined hub

5

together with thin thrust washers

6

and thrust bearing

7

.

5

Remove the two needle roller bearing assemblies

8

.

4-speed transmissions have only one needle roller bearing fitted.

6

*

Remove the thin thrust washer

9

, thrust bearing

10

, thin thrust washer

9A

(if fitted) and thick thrust washer

11

.

7

If end bearing

12

is to be removed it must be renewed.

Remove the bearing using puller. Discard the bearing.

Note:

This bearing would not normally be removed unless it was damaged. If a collet tool is not available, then it is permissible to use standard bearing puller, although damage to the bearing cage may be incurred which will require a new bearing.

8

Remove the clutch friction/counter plates retaining circlip

13

.

9

Remove pressure end plate

14

and shim

15

, if fitted.

10

Remove the clutch friction plates

16

and counter plates

17

. Keep them together in sets, DO NOT mix the plates with those from other clutches.

11

Position clutch assembly in a suitable press, with a cut away tube compress the piston spring as shown, then remove circlip

18

.

12

Lift off spring retaining plate

19

.

13

Remove the spring

20

and oil baffle

21

.

14

Turn the assembly over and knock the clutch shaft on a piece of aluminium (or wood) to loosen the piston

22

.

Note:

If the piston does not loosen when the clutch shaft is knocked on aluminium, then hand pump air down the shaft oil inlet hole.

15

Remove the piston

22

. Remove and discard the piston

‘O’ ring

23

and shaft ‘O’ ring

24

.

18

9803/3280

Purchased from www.WorkshopManuals.co.uk

A401360

Issue 2*

Section F

131 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

131 — 3

PS760 — Layshaft Clutch — Assembly

11A

9

10

9A

11/11A

8

5

4

6

7

6

3

6

5

9 9A B

B

9803/3280

3

4

7

8

10 11

Purchased from www.WorkshopManuals.co.uk

A405340

Issue 3*

Section F

131 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

131 — 4

PS760 — Layshaft Clutch — Assembly

End Float Setting — Plate Carrier and Gear

(Only clutch assemblies fitted with thrust washer

9A

)

Later clutch assemblies feature an additional thrust washer

9A

. If any of the components listed below are to be renewed, the end float of gear

5

must be measured and reset as required:

Item

B

Shaft assembly

5

Gear and plate carrier assembly

6,7

Thrust washer assembly

9,10

Thrust washer assembly

4

4WD transfer gear or spacer as applicable

Check and reset the endfloat of gear

5

as follows:

1

Temporarily fit thick thrust washer

11

, thin thrust washer

9A,

thrust bearing

10

and thin thrust washer

9

. Fit needle roller bearing

8

.

2

Temporarily fit the gear and plate carrier assembly

5

. Fit the thin thrust washer

6

and thrust bearing

7

followed by the remaining thrust washer

6

.

3

Temporarily fit the 4 wheel drive transfer gear

4

onto the layshaft spline. Make sure that the gear is fitted the correct way round. 2 wheel drive machines have a spacer fitted instead of a gear. Fit the circlip

3

.

4

Make sure that the 4 wheel drive gear (or spacer) is fully seated against circlip

3

. Measure the end float of gear

5

.

It must be between 0.01 to 0.15 mm (0.0004 to 0.006 in)

If the end float requires adjustment select a suitable thrust washer from

11A

and reassemble the components as described above.

Note:

11A

= kit 823/10420 — comprises 6 thrust washers of the following thicknesses:

4.3 mm (0.169 in)

4.4 mm (0.173 in)

4.5 mm (0.177 in)

4.6 mm (0.181 in)

4.7 mm (0.185 in)

4.8 mm (0.189 in)

5

Recheck the end float and then dismantle the components. Assemble the clutch as detailed on the next page. Be sure to fit the correct thrust washer

11

on final assembly.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 3*

Section F

131 — 5

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

131 — 5

PS760 — Layshaft Clutch — Assembly

8

8

9

10

9A

11

5

4

6

7

6

1

2

3 17

16

13

14

15

12

18

19

20

21

22

23

24

1

2

6

5

13

14 16

17

24

A396160

A402700

12

13

14

A

9803/3280

3

4

7

8

11

15

18

20

19

22

21

23

Purchased from www.WorkshopManuals.co.uk

A396230

Issue 1

Section F

131 — 6

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

131 — 6

PS760 — Layshaft Clutch — Assembly

Visually inspect the friction and counter plates:

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

9

* Fit the thick thrust washer thrust bearing

10

11

, thin thrust washer and thin thrust washer

9

.

*

†

Thrust washer

9A

not fitted to early clutch assemblies.

9A

†

,

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

10

Fit the two needle roller bearings

8

. The 4-speed transmissions have only one needle roller bearing fitted.

DO NOT mix old and new plates, if a plate is damaged/worn fit a complete new set.

11

Carefully align the teeth of the clutch plates using a thin rod (or screwdriver) and fit the gear and splined hub

5

.

12

Fit the thin thrust washers

6

and thrust bearing

7

.

Needle roller bearings should slide into position freely, do not bend or distort the cage to fit. If the cage has been distorted fit new bearings.

13

Fit the 4 wheel drive transfer gear

4

onto the layshaft spline. Make sure that the gear is fitted the correct way round. The 2 wheel drive machines have a spacer fitted instead of a gear. Fit the circlip

3

.

Note:

The piston incorporates a small check valve. Visually inspect the piston to ensure the ball is in place and that the seat is free from contamination. If necessary clean the valve by blowing through with an air line. DO NOT use a wire rod

(or screwdriver) as damage to the valve seat could occur.

14

Smear the clutch end bearings

2

and

12

with gearbox oil. Oil and press the bearings onto the shaft.

15

Fit piston ring seals

1

, refer to

Piston Ring Seals —

Fitting Procedure

.

1

Fit new ‘O’ rings

24

and

23

. Lubricate the piston

22

with oil and press fully into bore of clutch housing.

2

Fit oil baffle

21

, piston spring

20

, make sure the spring seats in the piston.

3

Fit the spring retaining plate

19

.

4

Compress the spring and secure with circlip

18

.

5

Fit one counter plate

17

followed by one friction plate

16

. Continue fitting alternate counter and friction plates, finishing with a friction plate.

6

Fit the pressure end plate

14

, do not fit shim

15

at this stage. Make sure that the chamfered face is fitted facing the clutch pack as shown at

A

. Make sure the teeth are not aligned with the lubrication slots in the housing.

Note

: A spring disc is not fitted in this clutch pack.

7

Fit the clutch friction/counter plates retaining circlip

13

.

8

Using a dial test indicator as shown, measure the end float of the pressure end plate

14

, which should be 1.9

to 2.5 mm (0.075 to 0.098 in).

If it is necessary to adjust the end float to bring it within tolerance, there is a choice of fitting a 6.0mm (0.23in) or

6.5mm (0.25in) thick pressure end plate

14

, with either a shim

15

or an extra counter plate

17

between the retaining circlip

13

and pressure end plate

14

.

Use an airline to check the operation of the clutch.

217590

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

132 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

132 — 1

PS760 — Mainshaft Clutch — Dismantling

4

3

14

2

17

16

15

12

11

13

1

1

20

18

9

12

(4-speed type)

19

8

7

6

5

10

9803/3280

1

2 3 4

18

19 15 10 9

7

5

A396150

20

6

17

14

16 13 12 11 8

A396250

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

132 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

132 — 2

PS760 — Mainshaft Clutch — Dismantling

Note:

The illustration shows a mainshaft assembly for a 6 speed transmission. The mainshaft assembly for a 4 — speed transmission has some small differences. An explanation of the differences will be given as they occure in the procedure.

The mainshaft assemblies for the 6 — speed and the 4 speed transmission are the same basic construction, except the 4 — speed transmission have fewer friction/ counter plates.

1

Carefully remove piston ring seals

1

.

Note:

If the piston ring seals are excessively worn then check for burrs or damage on shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.

2

Remove taper roller bearing

2

using a puller or press.

3

Withdraw the gears

3

and

4

. Make a note which way round the gears are fitted for assembly.

4

At the opposite end, use a suitable puller to remove the taper roller bearing

5

.

5

Remove the clutch friction/counter plates retaining circlip

6

.

6

Remove the pressure end plate

7

and shim

8

, if fitted.

7

Remove the clutch friction plates

9

and counter plates

10

. Keep them together in sets, DO NOT mix the plates with those from other clutches.

8

Position clutch assembly in a suitable press, with a cut away tube compress the piston spring as shown, then remove circlip

11

.

9

Lif t o f f sp ring ret aining p lat e

12

. The 4 — sp eed transmissions have a different shaped spring retaining plate fitted.

10

Remove the spring

13

and oil baffle

14

.

11

Turn the assembly over and knock the clutch shaft on a piece of aluminium (or wood) to loosen the piston

15

.

Note:

If the piston does not loosen when the clutch shaft is knocked on aluminium, then hand pump air down the shaft oil inlet hole.

12

Remove the piston

15

. Remove and discard the piston

‘O’ ring

16

and shaft ‘O’ ring

17

.

13

Remove circlip

18

and withdraw the clutch housing

19

from the shaft. Remove and discard the ‘O’ ring

20

.

11

A401360

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

132 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

132 — 3

PS760 — Mainshaft Clutch — Assembly

4

3

14

2

17

16

15

12

11

13

1

1

20

18

9

12

(4-speed type)

19

8

7

6

5

10

1

2 3 4

9803/3280

18

19 15 10

9

7

5

20

6

17

14

16 13 12

11

8

A396250

Purchased from www.WorkshopManuals.co.uk

A

A396150

6

8

A402700

Issue 2*

Section F

132 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

132 — 4

PS760 — Mainshaft Clutch — Assembly

Visually inspect the friction and counter plates:

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

DO NOT mix old and new plates, if a plate is damaged/worn fit a complete new set.

Needle roller bearings should slide into position freely, do not bend or distort the cage to fit. If the cage has been distorted fit new bearings.

Note:

The piston incorporates a small check valve. Visually inspect the piston to ensure the ball is in place and that the seat is free from contamination. If necessary clean the valve by blowing through with an air line. DO NOT use a wire rod

(or screwdriver) as damage to the valve seat could occur.

1

Fit a new ‘O’ ring

20

.

2

Press the clutch housing

19

onto the shaft spline and fit circlip

18

.

3

Fit a new ‘O’ rings

17

and

16

. Lubricate the piston

15

with oil and press fully into bore of clutch housing.

4

Fit oil baffle

14

, piston spring

13

, make sure the spring seats in the piston.

5

Fit the spring retaining plate

12

. The 4 — speed transmissions have a different shaped spring retaining plate fitted.

6

Compress the spring and secure with circlip

11

.

7

Fit one counter plate

8

followed by one friction plate

9

.

Continue fitting alternate counter and friction plates, finishing with a friction plate.

*

8

Fit pressure end plate

7

. Make sure that the chamfered face is fitted facing the clutch pack as shown at

A

.

Make sure the teeth are not aligned with the lubrication slots in the housing. Do not fit shim

7

at this stage.

Note

: A spring disc is not fitted in this clutch pack.

9

Fit the clutch friction/counter plate retaining circlip

6

.

10

Using a dial test indicator as shown, measure the end float of the pressure end plate

7

, which should be 1.9 to

2.5 mm (0.075 to 0.098 in).

If it is necessary to adjust the end float to bring it within tolerance, there is a choice of fitting a 6.0mm (0.23in) or

6.5mm (0.25in) thick pressure end plate

7

, with either a shim

8

or an extra counter plate

10

between the retaining circlip

6

and pressure end plate

7

.

9803/3280

Use an airline to check the operation of the clutch.

11

Smear the taper roller bearing

5

with gearbox oil and press the bearing onto the shaft.

12

At the opposite end press gears

3

and

4

onto shaft spline. Make sure that the gears are fitted the correct way round.

13

Smear the taper roller bearing

2

with gearbox oil and press the bearing onto the shaft.

14

Fit piston ring seals

1

, refer to

Piston Ring Seals —

Fitting Procedure

.

217590

Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section F

133- 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

133 — 1

PS760 — 6 Speed Clutch — Dismantling

23

24

25

14

15

13

1

2

3

16

17

20

19

22

21

2

3

18

9

8

7

6

4

1

5

12

11

10

25

18

16 17

15

13

19

A396170

12

9

7

1

9803/3280

23

22

24

21

14 20

6

8

5

A396240

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

133- 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

133 — 2

PS760 — 6 Speed Clutch — Dismantling

1

Carefully remove piston ring seals

1

at each end of the shaft.

Note:

If the piston ring seals are excessively worn then check for burrs or damage on shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.

2

Remove taper roller bearing

2

using a collet tool and press.

3

Withdraw the gear

3

. Make a note which way round the gear is fitted for assembly.

4

At the opposite end, remove the clutch end bearing

4

using a puller.

5

Withdraw the gear and splined hub

5

together with thick thrust washer

6

, thrust bearing

7

and thin thrust washer

8

.

6

Remove the needle roller bearing

9

.

7

Remove the thin thrust washer

10

, thrust bearing

11

and thick thrust washer

12

.

8

Remove the clutch friction/counter plates retaining circlip

13

.

9

Remove pressure end plate

14

and shim

15

, if fitted.

10

Remove the clutch friction plates

16

and counter plates

17

. Keep them together in sets, DO NOT mix the plates with those from other clutches.

11

Remove the disc spring assembly

18

.

12

Position clutch assembly in a suitable press, with a cut away tube compress the piston spring as shown, then remove circlip

19

.

13

Lift off spring retaining plate

20

.

14

Remove the spring

21

and oil baffle

22

.

15

Turn the assembly over and knock the clutch shaft on a piece of aluminium (or wood) to loosen the piston

23

.

Note:

If the piston does not loosen when the clutch shaft is knocked on aluminium, then hand pump air down the shaft oil inlet hole.

14

Remove the piston

23

. Remove and discard the piston

‘O’ ring

24

and shaft ‘O’ ring

25

.

19

A401360

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

133- 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

133 — 3

PS760 — 6 Speed Clutch — Assembly

23

24

25

1

2

3

14

15

13

9803/3280

2

3

22

21

20

19

16

17

18

9

8

7

6

4

1

5

12

11

10

25

18

16 17

15

13

19

12

9

7

1

A396170

A

13

14

23

22

24

21

14 20

6

8

5

A396240

Purchased from www.WorkshopManuals.co.uk

A402700

Issue 2*

Section F

133- 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

133 — 4

PS760 — 6 Speed Clutch — Assembly

Visually inspect the friction and counter plates:

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

DO NOT mix old and new plates, if a plate is damaged/worn fit a complete new set.

Needle roller bearings should slide into position freely, do not bend or distort the cage to fit. If the cage has been distorted fit new bearings.

Take care when handling disc spring assemblies

18

to avoid marking or damage, which could result in stress cracking. If in doubt fit a new disc spring.

Note:

The piston incorporates a small check valve. Visually inspect the piston to ensure the ball is in place and that the seat is free from contamination. If necessary clean the valve by blowing through with an air line. DO NOT use a wire rod

(or screwdriver) as damage to the valve seat could occur.

1

Fit new ‘O’ rings

25

and

24

. Lubricate the piston

23

with oil and press fully into bore of clutch housing.

2

Fit oil baffle

22

, piston spring

21

, make sure the spring seats in the piston.

3

Fit the spring retaining plate

20

.

4

Compress the spring and secure with circlip

19

.

5

Fit the disc spring assembly

18

. Make sure that the disc spring is fitted with the teeth towards the clutch pack.

Make sure the teeth are not aligned with the lubrication slots in the housing.

6

Fit one counter plate

17

followed by one friction plate

16

. Continue fitting alternate counter and friction plates, finishing with a friction plate.

*

7

Fit the pressure end plate

14

, do not fit shim

15

at this stage. Make sure that the chamfered face is fitted facing the clutch pack as shown at

A

. Make sure the teeth are not aligned with the lubrication slots in the housing.

8

Fit the clutch friction/counter plates retaining circlip

13

.

9

Using a dial test indicator as shown, measure the end float of the pressure end plate

14

, which should be 1.9

to 2.5 mm (0.075 to 0.098 in).

If it is necessary to adjust the end float to bring it within tolerance, there is a choice of fitting a 6.0mm (0.23in) or

6.5mm (0.25in) thick pressure end plate

14

, with either a shim

15

or an extra counter plate

17

between the retaining circlip

13

and pressure end plate

14

.Use an airline to check the operation of the clutch.

10

Fit the thick thrust washer

12

, thrust bearing

11

and thin thrust washer

10

.

11

Fit the needle roller bearing

9

.

12

Carefully align the teeth of the clutch plates using a thin rod (or screwdriver) and fit the gear and splined hub

5

.

13

Fit the thin thrust washer

8

, thrust bearing

7

and thick thrust washer

6

.

14

Smear the clutch end bearing

4

with gearbox oil and press the bearing onto the shaft.

15

At the opposite end, press the gear

3

onto the shaft spline. Make sure that the gear is fitted the correct way round.

16

Smear the clutch end bearing

2

with gearbox oil and press the bearing onto the shaft.

17

Fit piston ring seals

1

at each end of the shaft, refer to

Piston Ring Seals — Fitting Procedure

.

9803/3280

217590

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

134 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

PS 760 — 2/4WD Clutch (Pressure ON) — Dismantling

Section F

134 — 1

9803/3280

7

3

2

10 9 12 11

18 1

4

6

5

8

14 13

15

15a

16

17

A396260

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

134 — 2

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

PS 760 — 2/4WD Clutch (Pressure ON)

—

Dismantling

1

Remove bearing

1

, only if to be renewed.

2

Carefully remove piston ring seal

2

. Note, If the piston ring seal is damaged or excessively worn then check for burrs or damage on the shaft groove. If necessary remove burrs with a fine grade abrasion paper and oil.

3

Using a puller or press, withdraw the 4WD gear and splined hub

5

, together with its bearing

3

, needle roller bearings

6

and thrust washer

4

. Remove thrust washer

7

. (No t e t hat t hrust w ashers

4

and

7

are no t interchangeable).

4

Remove the clutch friction/counter plates retaining circlip

8

.

5

Remove pressure end plate

10

and shim

9

, if fitted.

6

Remove the clutch friction plates

11

and counter plates

12

. Keep them together in sets, DO NOT mix the plates with those from other clutches.

7

Position clutch assembly in a suitable press, with a cut away tube compress the piston spring as shown, then remove circlip

13

.

8

Lift off spring retaining plate

14

.

9

Remove the spring

15

and oil baffle

15A

.

10

Turn the assembly over and knock the clutch shaft on a piece of aluminium (or wood) to loosen the piston

16

.

Note:

If the piston does not loosen when the clutch shaft is knocked on aluminium, then hand pump air down the shaft oil inlet hole.

11

Remove the piston

16

. Remove and discard the piston

‘O’ ring

17

and shaft ‘O’ ring

18

.

13

Section F

134 — 2

A401360

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

134 — 3

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

134 — 3

PS 760 — 2/4WD Clutch (Pressure ON) — Assembly

9803/3280

A402700

8

10

A

7

3

2

10 9 12 11

18

1

4

6

5

8 14 13

15

16

15a

17

A396260

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section F

134 — 4

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

134 — 4

PS 760 — 2/4WD Clutch (Pressure ON)

— Assembly

Visually inspect the friction and counter plates:

Counter plates — light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set.

Friction plates — the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set.

DO NOT mix old, new and worn plates, if a plate is damaged/worn fit a complete new set.

Needle roller bearings should slide into position freely, do not bend or distort the cage to fit. If the cage has been distorted fit new bearings.

Note:

The piston incorporates a small check valve. Visually inspect the piston to ensure the ball is in place and that the seat is free from contamination. If necessary clean the valve by blowing through with an air line. DO NOT use a wire rod

(or screwdriver) as damage to the valve seat could occure.

1

Fit new ‘O’ rings

17

and

18

. Lubricate the piston

16

with oil and press fully into bore of clutch housing.

2

Fit oil baffle

15A

, piston spring

15

, make sure the spring seats in the piston.

3

Fit the spring retaining plate

14

.

4

Compress the spring and secure with circlip

13

.

5

Fit one counter plate

12

followed by one friction plate

11

. Continue fitting alternate counter and friction plates, finishing with a friction plate.

*

6

Fit the pressure end plate

10

, do not fit shim

9

at this stage. Make sure that the chamfered face is fitted facing the clutch pack as shown at

A

. Make sure the teeth are not aligned with the lubrication slots in the housing.

7

Fit the clutch friction/counter plates retaining circlip

8

.

8

Using a dial test indicator as shown, measure the end float of the pressure end plate

10

, which should be 1.9

to 2.5 mm (0.075 to 0.098 in).

If it is necessary to adjust the end float to bring it within tolerance, there is a choice of fitting a 6.0mm (0.23in) or

6.5mm (0.25in) thick pressure end plate

10

, with either a shim

9

or an extra counter plate

12

between the retaining circlip

8

and pressure end plate

10

.

Use an airline to check the operation of the clutch.

9

Fit thrust washer

7

.

10

Carefully align the teeth of the clutch plates using a thin rod (or screwdriver) and fit the 4WD gear and splined hub

5

, needle roller bearings

6

and thrust washer

4

.

11

Smear the clutch end bearing

3

with gearbox oil and press the bearing onto the shaft to seat on thrust washer

4

.

12

Fit piston ring seal

2

, refer to

Piston Ring Seals —

Fitting Procedure

.

217590

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section F

140 — 1

www.WorkshopManuals.co.uk

Transmission

Powershift Gearbox

Section F

140 — 1

Polytetrafluoroethylene (PTFE) Piston Ring Seals — Fitting Procedure

See

Synchro Shuttle Gearbox, Piston Ring Seals — Fitting

Procedure.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section F

150 — 1

www.WorkshopManuals.co.uk

Transmission

Torque Converter

Section F

150 — 1

Torque Converter

Removal

See the relevant gearbox removal procedure for torque converter removal.

Replacing

Ensure that flywheel face, drive plate, and hardware are clean and free from burrs or other surface imperfections.

When Replacing

1

Offer drive plate

1

to the torque converter.

2

Place the torque converter alignment tool

A

over the torque converter spigot, make sure that the tool locates in two of the converter bolt holes as shown. It is important to note that the converter drive tube must be protected against damage or contamination at all times.

3

Fit four of the M10 flanged bolts

2

and torque tighten to

84 Nm (62 lbf ft). Remove the alignment tool and fit the remaining two retaining bolts

2

.

4

Offer the torque converter and drive plate assembly to the flywheel, bolt the drive plate to the flywheel (use only 3 bolts). Check the converter run-out as shown at

B

, which should not exceed 0.38mm (0.015 in.).

Note:

In the unlikely event that the run-out exceeds 0.38 mm

(0.015 in.), remove the converter and check the spigot for burrs, remove the drive plate and rotate it 180° on the torque converter, repeat steps

2

to

4

.

5

Remove the torque converter and drive plate assembly from the flywheel.

6

Install the torque converter with its drive plate assembly onto the transmission input shaft, make sure that the dogs on the converter pump drive shaft engage with the recesses in the pump, also take care not to damage the oil seal.

7

Rotate the engine flywheel so that one bolt hole is in a six O’ clock position.

8

Rotate the torque converter and drive plate assembly so that one bolt hole is in a six O’ clock position.

9

Install the transmission/torque converter assembly to the engine. See the relevant gearbox replacement procedure.

It is vitally important that the torque converter is fitted at the gearbox and engine flywheel correctly

. Failure to locate the converter correctly will result in damage to the gearbox oil pump on engine start up.

10 Remove the access plate from the bottom of the engine flywheel housing and through the access hole fit and hand tighten one M8 flanged bolt (item 3) in the six ‘O’ clock position

11

Rotate the flywheel until the next bolt hole is accessible, fit and hand tighten the next bolt

3

. Repeat the operation until all bolts are fitted. Finally torque tighten bolts

3

to 44 Nm (32 lbf ft), rotating the flywheel each time to align bolts

3

with access hole. Refit access plate.

2 A

1

S267910

B

S161470

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section F

150 — 2

www.WorkshopManuals.co.uk

Transmission

Torque Converter

Section F

150 — 2

3

2

1

A265990

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

i

Section G

www.WorkshopManuals.co.uk

Brakes

Section G i

Contents

Technical Data

System type

Basic System Operation

Compensating Master Cylinder — Description

Pedals Locked — Normal Operation

Pedals Locked — Compensating Operation

Pedals Unlocked — Normal Operation

Fault Finding

Service Procedures

Service Brakes

— Brake Light Switch — Adjustment

— Brake Piston Seal Leakage Test

Parking Brake

— Testing

— Adjustment

— Switch Adjustment

— Renewing the Brake Pads

Master Cylinder and Servo Unit

Removal and Replacement

Dismantling and Assembly

Service Brakes

Dismantling and Assembly

Bleeding

Parking Brake

Torque Figures

Calliper Removal and Replacement

Calliper Dismantling and Assembly

Brake Disc — Removal and Replacement

Page No.

2 — 1

3 — 1

3 — 1

3 — 1

3 — 1

10 — 1

20 — 1

20 — 2

20 — 3

20 — 4

20 — 5

20 — 6

30 — 1

30 — 3

40 — 1

40 — 2

50 — 1

50 — 2

50 — 3

50 — 7

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

2 — 1

www.WorkshopManuals.co.uk

Brakes

Technical Data

Section G

2 — 1

System Type

Hydraulic servo assisted service brakes in rear axle only, operated from

* separate pedals. Independant cable operated parking brake in the drive to the rear wheels.

Service Brake

Type

Actuation

JCB Oil-immersed multi-plate disc

Hydraulic — vacuum servo assisted

Location

Friction Plates (5 per brake pack)

Outside Diameter

Inside Diameter

Nominal Facing Area per Plate

Hydraulic Piston Diameter

Rear axle centre casing (2 brake packs)

Master Cylinder (combined servo assistance)

Number of Cylinders 2

220 mm (7.992 in)

160 mm (6.299 in)

18603 mm 2 (28.8 in

216 mm (8.5 in)

2 )

Type

Piston Diameter (each)

Compensated master cylinder

22.22 mm (0.875 in)

Parking Brake

Type

Actuation

Disc brake, manually adjusted calliper

Cable operated

Location

Disc Diameter

* Mounted on the rear axle drive head.

279.4 mm (11 in)

Note:

Because the service brakes are located in the rear axle, instructions for dismantling and assembly are shown in Section

F —

Rear Axle Brakes

.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section G

3 — 1

www.WorkshopManuals.co.uk

Brakes

Basic System Operation

Section G

3 — 1

Compensating Master Cylinder

Description

Compensating master cylinders overcome the problem of unequal wear between the right and left brake. The units incorporate both master cylinder and compensating valve.

Each brake has its own master cylinder

A

,

A1

, brake pedals

B

,

B1

, servo units

N

,

N1

and associated pipework. Both master cylinders have one common reservoir

C

.

N ot e :

Dual p ed al b rak ing is ap p lic ab le o nly t o 2WS machines. 4WS machines have a single brake pedal.

Pedals Locked — Normal Operation

When the brake pedals are pushed down (the brake pedals are mechanically locked together), rod

D

pushes the plunger

E

down the bore of the master cylinder. Pressurised oil acting on centre valve seal

F

via valve stem

G

causes the seal to close off the reservoir supply port. As the plunger continues to move down the bore, pressurised oil flows to the brake pack

H

via service port

J

and the associated pipework.

Master cylinder

A1

operates in the same way to feed brake pack

H1

.

With valve stem

G

at maximum travel, further movement of plunger

E

causes valve

K

to lift off its seat. Both master cylinders are interconnected via bridge pipe

M

, therefore hydraulic pressure in both cylinders will be equal.

If the brake packs

H

and

H1

have worn equally, then the amount of oil d isp lac ement b et w een c ylind ers w ill b e minimal and the brakes will be applied evenly.

Pedals Locked — Compensating Operation

When the brake pedals are pushed down (the brake pedals are mechanically locked together), actuation of the brake packs

H

and

H1

is as described in Pedals Locked — Normal

Operation. If however, the brakes have not worn equally, then the amount of fluid displaced from each master c ylind er w ill vary and some form of c omp ensat ion is required.

Pedal application moves plungers

E

down the bores of master cylinders

A

and

A1.

Linings of brake

H

are brought into contact before the linings of brake

H1

because they have not worn as severely.

If further displacement took place at the linings, brake

H

w ould b e ap p lied b efore b rake

H1

. Therefore mast er cylinder

A

begins to compensate for master cylinder

A1

.

Fluid is displaced from

A

to

A1

via bridge pipe

M

until the p ressures are eq ualised . In t his c o nd it io n b o t h compensating valves are open and both brakes are applied evenly.

Pedals Unlocked — Normal Operation

When a single brake pedal is pushed down, rod

D

pushes t he p lunger

E

d ow n t he b ore of t he mast er c ylind er.

Pressurised oil acting on centre valve seal

F

via valve stem

G

causes the seal to close off the reservoir supply port. As the plunger continues to move down the bore, pressurised oil flow s t o t he b rake p ac k

H

via servic e p ort

J

and associated pipework, thus braking one wheel only.

With valve stem

G

at maximum travel, further movement of p lunger

E

c auses valve

K

t o lift off it s seat . Fluid is displaced through drillings

P

from the active cylinder

A

via bridge pipe

M

to passive cylinder

A1

. Valve

K1

in the p assive c ylind er is held on it s seat b y t he d isp lac ed pressurised fluid.

C

M

N1

J

A1

H1

B1

H

9803/3280

A

F G

K

E

P

D

N

B

Purchased from www.WorkshopManuals.co.uk

A265570

Issue 1

Section G

10 — 1

www.WorkshopManuals.co.uk

Brakes

Fault Finding

Section G

10 — 1

Brake System

Note:

The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. Note aslo that 4WS machines do not have dual pedal braking.

FAULT POSSIBLE CAUSE ACTION

A

One or both brakes do not apply.

(Brake travel not excessive, brakes not pulling to one side).

1 Master cylinder fault.

2 Friction/counter plate distortion.

B

Pedal travel excessive (but not touching floor).

1 Air in hydraulic system.

1 Check master cylinder in single and coupled pedal modes to identify fault area, service as required.

2 Check friction/counter plates.

1 Check fluid reservoir level. Check for fluid/air leaks, rectify as required.

2 Leak in hydraulic system.

2 Check for fluid loss at master cylinder and brake piston, all pipes and fittings for loose connections.

Rectify as required.

3 Friction/counter plate distortion.

C

Applying one brake (pedals unlocked) also partially engages the other brake.

1 Valve stem seal inside (non-active) master cylinder piston not sealing.

1 Renew master cylinder piston.

D

Pedal hard to operate.

1 Tightness at pedal pivot.

3 Renew friction/counter plates —

BOTH sides.

1 Inspect pedal pivot. Freeoff/lubricate.

2 Fluid contamination/seal damage.

2 Flush system and renew all hydraulic seals.

3 Misaligned push rod/pedal.

3 Check and rectify as required.

4 Kinked or crushed brake pipes.

Items 5 to 7 are for machines fitted with servo assisted brakes only:

4 Check/renew brake pipework.

5 Vacuum failure due to low vacuum at source.

5 Inspect/service engine mounted exhauster unit as required.

6 Blocked/leaking vacuum pipe.

6 Check/renew vacuum pipe.

7 Servo defect.

E

Pedals touch floor under constant pressure — no fluid loss.

1 Master cylinder fault.

F

Pedals touch floor under constant pressure — and fluid loss.

2

3

Friction/counter plate distortion.

Air in hydraulic system.

1 External fluid leaks.

7 Renew servo unit.

1 Check master cylinder in single and coupled pedal modes to identify fault area, service as required.

2 Renew friction/counter plates —

BOTH sides.

3 See item B.1.

1 Visually check brake circuit for fluid loss, service as required.

2 Internal fluid leaks.

2 Refer to

Service Procedures —

Brake Piston Seal Leakage Test

.

G

Pulling to one side when pedals locked together.

1 Compensating feature not working.

1 Inspect master cylinder compensating operation. Check if blockage in bridging pipe. Service as required.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section G

10 — 2

www.WorkshopManuals.co.uk

Brakes

Fault Finding

Section G

10 — 2

FAULT POSSIBLE CAUSE ACTION

G

Pulling to one side when pedals locked together (cont’d).

2 Braking system inoperative on one side.

2 Unlatch pedals to test circuits individually.

3 Friction plates worn beyond limits or distorted on one side.

3 Renew friction/counter plates —

BOTH sides.

4 Badly adjusted push rods.

4 Adjust push rod (1mm minimum).

5 Servo operating rod out of adjustment.

5 Adjust servo operating rod.

6 Annular piston fault (see item J6).

6 See item J6.

H

Poor braking (not pulling to one side).

1 Friction plates worn beyond limits or distorted on one side.

1 Renew friction/counter plates —

BOTH sides.

2 Master cylinder fault.

2 Check master cylinder in single and coupled pedal modes to identify fault area, service as required.

3 Annular piston fault (see item J6).

4 Incorrect/low axle oil.

3

4

See item J6.

Fill axle with correct type of oil.

5 Vacuum failure (machines fitted with servo assisted brakes only).

5 Inspect vacuum source/pipes, service as required.

J

One or both brakes not releasing.

1 Brake pedal spring fault.

1 Fit a new spring.

2 Master cylinder fault (plunger stuck in bore).

2 Service as required.

3 Blocked hole in master cylinder reservoir cap.

3 Fit a new reservoir cap.

4 Brake pedal free travel incorrect.

4 Adjust pedal free travel.

5 Fluid contamination/seal damage.

5 Flush system and renew hydraulic seals.

6 Annular brake piston(s) binding in axle.

6.1 Check that correct brake fluid has been used (incorrect fluid could swell the annular brake piston seals).

6.2 Check if annular brake piston seals in good condition.

6.3 Check that annular brake piston rotates freely in its housing with no seals fitted.

6.4 Check that the annular brake piston seal retracts the piston approximately 0.5mm (0.020 in).

7 Kinked or crushed brake pipes.

7 Check and renew pipes as required.

8 Friction/counter plates not free on splines and/or dowels.

8 Check friction/counter plates for free movement, replace if required —

BOTH sides.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section G

10 — 3

www.WorkshopManuals.co.uk

Brakes

Fault Finding

Section G

10 — 3

FAULT

K

Poor braking when hot.

POSSIBLE CAUSE ACTION

1 Moisture in system vapourizing when axle is hot.

1 Strip axle and clean annular piston to remove moisture. Remove master cylinders and check for corrosion, service as required. Flush hydraulic brake system.

L

Excessive brake noise in operation.

1 Deterioration of axle oil or wrong type of axle oil.

1 Change axle oil.

Note:

Due to the metal to metal contact of oil immersed brakes, limited noise can be heard which is consistent with this type of design — this is normal.

2 Axle oil loss.

2 Refill axle with correct oil and check for leaks.

3 Friction plates worn beyond limits.

3 Renew friction/counter plates.

4 Friction/counter plates in poor condition.

4 Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable).

M

Fluid loss when machine standing, for instance — overnight (see note).

Note:

Confirm fault is as indicated by checking that the pedals DO NOT touch floor under constant pressure.

1 Slight cut or nick in the brake piston seal, refer to

Service

Procedures — Brake Piston Seal

Leakage Test

.

1 Strip axle, replace seal.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

20 — 1

www.WorkshopManuals.co.uk

Brakes

Service Procedures

Section G

20 — 1

Service Brakes

Brake Light Switch — Adjustment

1

Select the starter key switch to the ON position, do not start the engine.

2

With the brake pedal in the return position, adjust locknuts

B

and use feeler gauges to set the proximity switch

A

so that there is clearance of 2mm MIN — 3mm

MAX between the end of the switch and the brake pedal lever. The light emitting diode (L.E.D.) on the switch should be illuminated.

3

Secure the switch in position by tightening locknuts

B

.

4

Depress the brake pedal and check the correct operation of the brake lights.

Torque Settings

Item

B

Nm

29 kgf m lbf ft

2.95

21

A

B

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

20 — 2

www.WorkshopManuals.co.uk

Brakes

Service Procedures

Section G

20 — 2

Service Brakes

Brake Piston Seal Leakage Test

The following procedure explains how to check if a brake piston seal is severely damaged/perished or if the seal has a small cut or nick. The test must only be done when the axle is COLD.

!

WARNING

Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK 1-4

!

WARNING

Do not drive the machine with any part of its brake system disconnected. When the following test has been completed reconnect all brake pipes and bleed the brake system using the recommended procedure.

BRAK 2-1

1

Remove and cap brake piston feed pipe

A

.

2

Fill the brake piston housing with JCB Light Hydraulic

Fluid.

3

Check for severe piston seal damage:

a

Install a hand pump fitted with a 0 — 40 bar (0 — 600 lbf/in

2

) pressure gauge to port

B

, as shown at

X.

Note

: The hand pump MUST be filled with JCB Light

Hydraulic Fluid. DO NOT exceed 69bar (1000 lbf/in

2

).

b

Use the hand pump to generate a pressure in the brake piston housing.

c

If the pressure falls off rapidly, or if no pressure reading can be obtained, the seal is severely damaged and needs replacing with a new one.

4

Check for small cuts or nicks in the piston seal:

a

Install an adapter fitted with a piece of clear tube to the brake piston port

B

, as shown at

Y

.

Note

: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine.

b

Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid

c

Using a suitable pen, mark the level line of the brake fluid on the tube, as shown at

C

.

d

After approximately 1/2 hour, check if the level has dropped below the original marked line, if it has then check the brake piston seal for slight nicks, cuts or generally for wear.

5

Repeat steps 1 to 4 for the opposite brake piston seal.

6

Reconnect all brake pipes and bleed the brake system.

Refer to

Service Brakes — Bleeding

.

X

159830X

Y

159830Y

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section G

20 — 3

www.WorkshopManuals.co.uk

Brakes

Service Procedures

Section G

20 — 3

Parking Brake — Testing

SAFETY NOTICE:

Ensure all routine health and safety precautions are observed before operating machines.

!

WARNING

Before testing the parking brake make sure the area around the machine is clear of people.

2-2-4-5

1

Enter the machine. Fasten your seat belt and park the machine on a level dry surface.

2

Fully apply the parking brake

1

.

3

On machines with two brake pedals ensure they are locked together.

4

Start the engine and raise the attachments to the appropriate travelling position

.

5

Select fourth gear,

2

for syncro shuttle machines or

3

for powershift machines.

6

Push down hard on foot brake pedal

4

.

7

Select forward drive

5

.

!

WARNING

If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed.

2-2-5-1

Test the parking brake as follows:

8

Move the parking brake lever fractionally forward until the warning light

6

is just extinguished.

9

Slowly release the foot brake pedal

4

.

10

If the machine has not moved, use the accelerator pedal to gradually increase the engine speed to 1500

RPM. The machine should not move.

11

Do not do this test for longer than 20 seconds.

12

Reduce the engine speed to idle and select neutral

5

.

13

Return the park brake lever

1

to the fully on position from its partially applied position.

14

Lower attachments and stop the engine.

15

If the machine moved during this test, adjust the parking brake and repeat the test. See

Service

Procedures, Parking Brake — Adjustment

.

If you have any queries concerning this test procedure or parking brake adjustment, consult your local JCB distributor.

!

WARNING

Do not use a machine with a faulty parking brake.

3-2-3-10

!

CAUTION

Non approved modifications to axle ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.

3-2-3-11

3

5

6

4

2

1

6

A394410

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

20 — 4

www.WorkshopManuals.co.uk

Brakes

Service Procedures

Section G

20 — 4

Parking Brake — Adjustment

!

CAUTION

The parking brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced.

Whenever the parking brake has been used in an emergency, always renew both brake pads.

4-2-1-1/2

!

WARNING

Before working on the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

2-3-2-4/1

The parking brake should be fully engaged when the lever is vertical. The parking brake indicator light should light when the brake is engaged with the forward/reverse lever away from neutral (starter switch at IGN).

!

WARNING

Over adjustment of the parking brake could result in the parking brake not fully releasing

0011

Lever Adjustment

1

Disengage the parking brake (lever horizontal).

2

Turn handle grip

E

clockwise, half a turn.

3

Test the parking brake, refer to

Parking Brake —

Testing

.

4

If the brake fails the test, repeat steps

1

,

2

and

3

. If there is no more adjustment and pin

F

is at the end of its travel adjust the cable.

Cable Adjustment

Adjust the cable at the calliper if there is insufficient adjustment at the parking brake lever.

If there is no adjustment at the lever or the calliper, change the brake pads, refer to

Parking Brake — Renewing the

Brake Pads

.

Always renew a worn or damaged cable.

1

Disengage the parking brake (lever horizontal).

2

Turn hand grip

E

anti-clockwise to centre the pin

F

in its slot.

3

Release the two locknuts at

B

and adjust the cable length to give 10 to 15mm (0.40 to 0.60 in) of caliper lever movement at the outer cable fixing hole

H

. The total clearance between the brake pad to brake disc should be 0.5 to 0.75 mm (0.02 to 0.3 in).

4

Make sure there is adequate freedom of movement of operating lever

C

to ensure a positive brake application, and that the lever returns to the rest position when the parking brake is released.

5

Test the parking brake, refer to

Parking Brake —

Testing

. Make final adjustments at the park brake lever if the brake fails the test. Refer to

Lever Adjustment

.

B

H

B

E

F

C

A390850

A396181

9803/3280 Issue 2*

Purchased from www.WorkshopManuals.co.uk

Section G

20 — 5

www.WorkshopManuals.co.uk

Brakes

Service Procedures

Section G

20 — 5

Parking Brake — Switch Adjustment

1

Select the starter key switch to the ON position, do not start the engine.

2

Select either forward or reverse.

3

Raise the handbrake to the ON position.

4

Adjust locknuts

B

and use feeler gauges to set the proximity switch

A

so that there is clearance of 2mm

MIN — 3mm MAX between the end of the switch and the handbrake lever. The light emitting diode (L.E.D.) on the switch should be illuminated and the audible alarm should sound.

5

Secure the switch in position by tightening locknuts

B

.

6

Release the parking brake and the audible alarm should cease.

For adjustment of the Parking Brake, refer to

Parking Brake

— Adjustment

.

Torque Settings

Item

B

Nm

29 kgf m lbf ft

2.95

21

9803/3280

B B

A

A396440

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

20 — 6

www.WorkshopManuals.co.uk

Brakes

Service Procedures

Section G

20 — 6

Parking Brake — Renewing the Brake Pads

!

WARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Installation and mounting of the parking brake calliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available.

0010

!

WARNING

Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

!

WARNING

Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

Pad Removal

1

Remove the parking brake calliper from the axle mounting bracket, refer to

Parking Brake — Calliper

Removal and Replacement

.

2

Press carrier side pad

1

into housing

15

and remove.

Ensure any residual silicone used for pad retention during assembly is removed.

3

Carefully lever pad

2

from the rotor inside the housing using a flat blade screwdriver. Take care to prevent damage to the plastic clip in the centre of the rotor

9

(there is no need to remove the rotor from the calliper).

Pad Inspection

!

WARNING

Oil on the brake disc will reduce brake effectiveness.

Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer’s safety instructions. If the pads are oily, new ones must be fitted.

2-3-2-3/3

1

The minimum thickness of the friction material on either pad is 1mm (0.04 in), but it is recommended new pads are fitted as pads worn to this limit may not be able to be adjusted.

2

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn. For brake disc removal, refer to

Parking Brake, Brake Disc — Removal and

Replacement

.

3

Renew the cable if worn or damaged.

Pad Replacement

1

Fit the pad

2

to the lever side of the calliper. Position the pad inside housing

15

. Locate the plastic clip in the centre of the rotor

9

into the hole

X

, and press the pad into place.

2

Fit the pad

1

to the carrier sde of the calliper. Add a small amount of silicon sealant to the back outer edge of the backing plate to hold the pad in place within the housing.

3

Replace the calliper, refer to

Parking Brake — Calliper

Removal and Replacement

.

Note:

If there is insufficient adjustment after fitting new pads change the brake cable.

9

15

X

2

1

A390680

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section G

30 — 1

www.WorkshopManuals.co.uk

Brakes

Section G

30 — 1

G

A396450

F

B

B

K

E

D

H

H

E

9803/3280

Purchased from www.WorkshopManuals.co.uk

327340

Issue 1

Section G

30 — 2

www.WorkshopManuals.co.uk

Brakes

Master Cylinder and Servo Unit

Section G

30 — 2

Removal and Replacement

!

WARNING

Before working on the brake system make sure the machine is on level ground and chock all four wheels.

BRAK 1-4

Removal

1

Gain access the the brake pedal box assembly.

Remove the steering wheel, column switches and console assembly. See

Section D, Steering Column —

Removal

for procedures.

2

Working outside the cab, loosen and remove brake pipe unions

B

, plug and cap to prevent loss of fluid and ingress of dirt.

3

Remove the brake pipes from the master cylinders: master cylinders bridging pipe

D

; axle feed pipes

E

and reservoir supply pipes

H

.

4

Working inside the cab, remove the brake pedals clevis

F

and disengage the brake pedal from the servo unit

(both pedals).

5

Loosen and remove the servo unit retaining nuts

G

(both units).

6

Tag the cylinders (left and right hand). Remove the master cylinder and servo units.

Replacement

Replacement is a reversal of the removal sequence.

Refit the cylinders in their original positions.

If the brake master cylinders or brake servo units are removed it is recommended that the servo brake assembly operating rod measurement is checked.

If the rod length is not checked it may result in differing brake pedal travel which could result in uneven braking.

1

With the brake master cylinder removed, measure from the face of the servo unit to the end of the servo brake rod as shown at

J

which should be 8.5 to 8.3mm (0.334

to 0.326in).

2

Adjust measurement

J

by screwing domed bolt

K

in/out as required, secure in position with JCB Threadlocker &

Sealer.

Note

: If no adjustment is required make sure the domed bolt

K

can not be rotated by finger pressure.

!

WARNING

Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.

BRAK 1-1

3

Fill the brake system with JCB Light Hydraulic Fluid and bleed the system. Refer to

Service Brakes — Bleeding

.

Note:

4WS machines do not have dual pedal braking.

Procedures described still apply to a single pedal application.

4

Unlatch pedals and ensure that pedal pads are level with each other and fully back against their stops.

5

Adjust pedal linkages for free movement to give 1 mm

(0.040 in) on each pushrod.

6

With pedals still unlatched, apply an equal force to each pedal and check if pedals remain level. If necessary adjust by increasing the clearance on one of the pushrods. Do not decrease either clearance below 1 mm (0.040 in).

7

On completion bleed the brake system and check the brakes operate correctly and that machine stops in a straight line. Refer to

Service Brakes — Bleeding

.

8

Latch pedals and check for straight line braking; if satisfactory straight line braking cannot be achieved refer to

Fault Finding

.

Torque Settings

Item Nm kgf m lbf ft

H

30-34 3.0-3.5 22-25

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section G

30 — 3

www.WorkshopManuals.co.uk

Brakes

Master Cylinder and Servo Unit

Section G

30 — 3

Dismantling and Assembly

Note 1

: The servo unit (not shown) is a non serviceable part.

A faulty servo unit must be replaced with a new one.

Note 2

: Seal kits are no longer available for the master cylinders, the only servicing permitted is a major repair kit which comprises of a full piston assembly. A faulty master cylinder and piston assembly must be replaced with new ones.

Dismantling

1

Remove circlip

1

and washer

2

.

2

Shake the cylinder body, or use compressed air, to eject piston assembly

3

. Take care not to damage the piston assembly or the bore of the cylinder body.

3

Examine the working surfaces of piston and cylinder. If these are not in perfect condition the master cylinder assembly must be renewed. The piston assembly

3

cannot be dismantled. If it is damaged (including seal

5

), the complete piston/seal assembly must be renewed, see Note 2:

Assembly

!

WARNING

Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.

BRAK 1-1

1

Clean and lubricate all components, including new seals, with JCB Special Hydraulic Fluid. DO NOT USE

CONVENTIONAL BRAKE FLUID OR SERIOUS

DAMAGE WILL BE CAUSED.

2

Take care not to damage the machined faces of piston assembly

3

when assembling.

9803/3280

S151280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

40 — 1

www.WorkshopManuals.co.uk

Brakes

Service Brakes

Section G

40 — 1

Dismantling and Assembly

The service brakes are located in the rear axle, as shown at

A

. Instructions for dismantling and assembly of the brake are described in Section F —

Rear Axle Brakes

.

A

A264180

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

40 — 2

www.WorkshopManuals.co.uk

Brakes

Service Brakes

Section G

40 — 2

Bleeding

!

WARNING

Before proceeding with the bleeding procedure it is important to ensure that the parking brake is engaged and that one pair of wheels is blocked on both sides.

BRAK 1-2

!

WARNING

Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure.

BRAK 1-1

1

Fill the master cylinder reservoir with the correct fluid, refer to Section 3

Fluids, Lubricants, Capacities and

Specifications

, and ensure that throughout the bleeding process the level is not allowed to fall below the MINIMUM mark.

2

Unlatch the pedals, and bleed each brake separately as follows:

3

Right Hand Master Cylinder

a

Attach a tube to the right hand brake bleed screw

A

, ensuring that the free end of the tube is immersed in fluid contained in a suitable container.

b

Open the brake bleed screw and apply full pedal strokes of the right hand brake pedal until all air is expelled.

c

Close the brake bleed screw with the pedal fully depressed.

4

Left Hand Master Cylinder

a

Repeat procedure as for ‘ Right Hand Master

Cylinder’ but use left hand bleed screw and pedal.

5

Bridge Pipe

a

Attach a tube to either the left or right hand brake bleed screw, ensuring that the free end of the tube is immersed in fluid contained in a suitable container.

b

Make sure that the brake pedals are

locked

together.

Note:

4WS machines do not have dual pedal braking. These machines are fitted with a single pedal that operates both master cylinders.

c

Open the bleed screw and apply full pedal strokes of the brake pedals until all air is expelled.

d

Close the bleed screw with the pedals fully depressed.

6

Repeat the procedures as necessary.

7

Top up the reservoir to the full mark.

5

A

S107710-1

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section G

50 — 1

www.WorkshopManuals.co.uk

Brakes

Parking Brake

Section G

50 — 1

Torque Figures

The illustration shows a typical installation.

Where appropriate, the grade of bolt is indicated in parenthesis eg. (10.9). Refer also to relevant dismantling and assembly procedures.

Torque Settings

Item

A

B

C

Nm

166

lbf ft

122

13-15 9-12

255 188

(12.9)

(10.9 Tuflok)

C

A

A396540

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section G

50 — 2

www.WorkshopManuals.co.uk

Brakes

Parking Brake

Section G

50 — 2

Calliper Removal and Replacement

!

WARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Replacement

Replacement is the reverse of the removal sequence.

Installation and mounting of the parking brake calliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available.

0010

!

WARNING

Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

!

WARNING

Brake pads generate dust which if inhaled, may endanger health.

Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

Removal

1

Locate the calliper on the brake disc and fit new mounting bolts

C

with hardened washers, torque tighten to 255 Nm (188 lbf ft).

2

Insert cable into bracket

D

, do not tighten locknuts

B

at this stage as the brake will need adjusting.

*

3

Refit the clevis

A

into the hole in the operating lever

E

as shown.

4

Make sure there is adequate freedom of movement of operating lever

E

to ensure a positive brake application, and that the lever returns to the rest position when the parking brake is released.

5

Adjust the parking brake, see

Service Procedures,

Parking Brake Adjustment

.

Never unscrew the clevis A to adjust the cable.

Torque Settings

1

Release the parking brake lever (lever horizontal).

2

Disconnect clevis

A

, note which of the three holes on the lever is used.

Item

C

Nm

255

lbf ft

188

3

Undo locknuts

B

and disconnect the cable from the bracket

D

.

4

Support the calliper and remove the two mounting bolts and hardened washers

C

. Lift the calliper and bracket

D

clear of the brake disc.

Note:

Do not remove axle mounting bracket

F

unless it needs to be renewed.

B

B

C

A

D

E

C

F

A396181

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 2*

Section G

50 — 3

www.WorkshopManuals.co.uk

Brakes

Parking Brake

Section G

50 — 3

Component Listing:

1

Carrier Side Pad

2

Lever Side Pad

3

Bolt

4

Anti-rotation Clip

5

Washer

6

Washer

7

Lever

8

Spring

9

Rotor

10

Ball Spacer

11

Ball Bearings

12

Mounting Bush

13

O-ring

14

Shaft Seal

15

Housing

9803/3280

Purchased from www.WorkshopManuals.co.uk

228362

Issue 1

Section G

50 — 4

www.WorkshopManuals.co.uk

Brakes

Parking Brake

Section G

50 — 4

Calliper Dismantling and Assembly

Dismantling

The numerical sequence shown on the illustration on the adjacent page is intended as a guide to dismantling.

!

WARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Installation and mounting of the parking brake calliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available.

0010

!

WARNING

Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

!

WARNING

Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

1

Remove the calliper and brake pads, refer to

Calliper —

Removal and Replacement

.

2

Bend the tabs on anti-rotation clip

4

. Remove bolt

3

, anti-rotation clip

4

and washers

5

and

6

. Hold lever

7

against the tension of the spring as the bolt is removed.

3

Note the position of lever

7

and the splines of the shaft.

Mark the end of the shaft and lever

7

to aid assembly.

Remove lever

7

and spring

8

.

4

Push out rotor

9

and remove ball spacer

10

and ball bearings

11

. Take care not to lose the ball bearings.

5

Push out mounting bushes

12

and remove O-rings

13

.

Note:

Shaft seal

14

will not need to be renewed unless excessively worn or damaged. If removal is necessary, press the seal out from inside the housing using a suitable spacer block and bench press. Clean out any remains of the seal after removal.

Inspection

1

Clean and dry all parts. Check all parts are free from excessive wear, damage or corrosion. Light scores or stains should be removed. Renew corroded or deeply scored parts.

2

Check rotor

9

for damage or distortion. Renew if necessary.

Always renew both brake pads if the parking brake has been used in an emergency.

3

Check the ball pockets in housing

15

for signs of scoring, pitting, damage or corrosion. Renew the housing if damaged.

4

Check spring

8

is not broken or distorted.

5

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

www.WorkshopManuals.co.uk

13

13

12

10

4

7

14

3

5

6

8

15

13

13

12

11

Purchased from www.WorkshopManuals.co.uk

2

1

9

Section G

50 — 6

www.WorkshopManuals.co.uk

Brakes

Parking Brake

Section G

50 — 6

Dismantling and Assembly (cont’d)

Assembly

Before assembly make sure all parts are clean and serviceable.

1

Fit a new shaft seal

14

if removed. Install the seal as shown. Press the seal into the housing using a suitable spacer block and bench press.

2

Coat the the shaft and ball pockets of rotor

9

and the ball pockets of housing

15

with silicone grease.

3

Insert the three ball bearings

11

into the pockets in the housing

15

. Insert ball spacer

10

.

4

Slide rotor

9

through the casting and seat the ball pockets against the bearings.

5

Position spring

8

over the shaft of rotor

9

. Insert the large diameter end of the spring into hole

X

in the face of the housing.

6

Locate the small diameter end of spring

8

around the outside edge of lever

7

as shown at

Y

.

7

Fit lever

7

. Align the lever to the mark made during dismantling.

8

Hold the lever against the tension of the spring and fit washers

6

and

5

, and new anti-rotation clip

4

. Fit bolt

3

and tighten to 13-16 Nm (9-12 lbf ft).

9

Bend up a tab of the anti-rotation clip that aligns with one of the flats on the bolt.

10

Fit the new brake pads, refer to

Service Procedures —

Parking Brake — Renewing the Brake Pads

.

11

Lubricate the O-rings

13

and bushes

12

with silicone grease. Fit O-rings into the housing and insert mounting bushes. Wipe off any excess grease.

12

Before fitting the calliper, ensure the lever rotates smoothly and that the lever side pad

2

returns to the off position when the lever is released.

13

Refit the brake calliper. Refer to

Calliper — Removal and Replacement

.

14

Adjust the parking brake, refer to

Service Procedures

— Parking Brake — Adjustment

.

Torque Settings

Item

3

Nm

13-16

lbf ft

9-12

X

Y

A348331

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section G

50 — 7

www.WorkshopManuals.co.uk

Brakes

Parking Brake

Section G

50 — 7

Brake Disc — Removal and Replacement

!

WARNING

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

!

WARNING

Before working on the parking brake, park on level ground and put chocks each side of all four wheels. Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

Removal

1

Disconnect the propshaft to the rear axle, refer to

Section F

Propshafts — Removal and Replacement

.

2

Remove the calliper from the axle mounting bracket

F

, refer to

Calliper Removal and Replacement

.

3

Undo the stake nut and withdraw the brake disc from the drive pinion shaft.

Note:

If the axle is not mounted to a machine, fit flange spanner (service tool 992/04800) to prevent brake disc and drive pinion shaft turning when loosening or tightening the stake nut. Refer to Section F —

Service Tools

.

Replacement

Replacement is the reverse of the removal sequence.

1

Fit a new stake nut and torque tighten to 300 Nm (221 lbf ft), see Note:

2

Re-stake the nut using a square ended staking tool.

Torque Settings

Item

1

Nm

300 kgf m lbf ft

30.6

221

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

i

Section H

www.WorkshopManuals.co.uk

Steering

Contents

Service Tools

Page No.

1 — 1

Section H i

Technical Data

System Type

Basic System Operation

2 Wheel Steer Machines

— Steer System Schematics

— Hydraulic Operation

4 Wheel Steer Machines

— Steer System Schematics

— Hydraulic Operation

— Electrical Operation

Circuit Descriptions

Steer Unit Operation

— 2 Wheel Steer Machines

— 4 Wheel Steer Machines

4 Wheel Steer Mode

2 Wheel Steer Mode

Crab Steer Mode

Priority Valve Operation

Fault Finding

Service Procedures

Steering System

— Bleeding

— Pressure Testing

Proximity Switch — Setting

Steer Mode Valve — Checking Solenoid Operation

Priority Valve

— Cleaning

— Standby Pressure Testing

Power Track Rod

Removal and Replacement

Link Arms — Removal and Replacement

Rams — Dismantling and Assembly

Priority Valve

Removal and Replacement

Dismantling and Assembly

Bleeding

Steer Mode Valve

Removal and Replacement

Dismantling and Assembly

Hydraulic Steer Unit

Removal and Replacement

Dismantling and Assembly

2 — 1

4 — 1

4 — 2

4 — 13

4 — 14

5 — 1

10 — 1

20 — 1

20 — 2

20 — 3

20 — 4

20 — 5

20 — 6

3 — 1

3 — 2

3 — 3

3 — 4

3 — 5

30 — 1

31 — 1

32 — 1

40 — 1

40 — 1

40 — 1

45 — 1

45 — 2

50 — 1

50 — 3

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

1 — 1

www.WorkshopManuals.co.uk

Steering

Service Tools

Section H

1 — 1

S191750

892/0018 Seal Fitting Tool for fitting ‘O’ ring and kin ring to Hydraulic Steer Unit

Hexagon Spanners for Ram Pistons and End Caps

992/09300 55mm A/F

992/09400 65mm A/F

992/09500 75mm A/F

992/09600 85mm A/F

992/09700 95mm A/F

992/09900 115mm A/F

992/10000 125mm A/F

S193930

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

2 — 1

www.WorkshopManuals.co.uk

Steering

Technical Data

Section H

2 — 1

System Type

Full power hydrostatic with selectable 2-wheel, 4wheel and crab steer modes on 4 wheel steer machines.

Oil supply from Main Hydraulic Pump via Priority Valve to Steer Unit Valve complete with Load Sensing and

Integral Relief Valve.

Double acting power track rod rams mounted on axles.

2 Wheel Steer Machines

STEER UNIT — FIG 1

Model

— Volumetric Displacement

— Relief Valve

— Check Valve

— Shock Valve

— Relief Valve Operating Pressure (at 1500 revs/min)

-Shock Valve Operating Pressure

Model

— Volumetric Displacement

— Relief Valve

— Check Valve

— Shock Valve

— Relief Valve Operating Pressure (at 1500 revs/min)

PRIORITY VALVE — FIG 2

—

Stand by Pressure

4 Wheel Steer Machines

STEER UNIT — FIG 1

Model

— Volumetric Displacement

— Relief Valve

— Check Valve

— Shock Valve

— Relief Valve Operating Pressure (at 1500 revs/min)

— Shock Valve Operating Pressure

PRIORITY VALVE — FIG 2

—

Stand by Pressure

200 OSPC

200 cc/rev

Fitted

Fitted

Fitted

120 ± 3 bar 122 ± 3.5 kgf/cm

2

175 — 190bar 178 — 199 kgf/cm

2

250 OSPC

250 cc/rev

Fitted

Fitted

Not Fitted

120 ± 3 bar 122 ± 3.5 kgf/cm

2

7 bar

7 bar

1740 ± 50 lbf/in

2

2538 — 2756 lbf/in

2

1740 ± 50 lbf/in

2

7.1 kgf/cm

2

102 lbf/in

2

160 OSPC

160 cc/rev

Fitted

Fitted

Fitted

120 ± 3 bar 122 ± 3.5 kgf/cm

2

175 — 190bar 178 — 199 kgf/cm

2

1740 ± 50 lbf/in

2

2538 — 2756 lbf/in

2

7.1 kgf/cm

2

102 lbf/in

2

A263810

9803/3280

LS

EF

LS

P

A263820

LS

FIG 1

FIG 2

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

3 — 1

www.WorkshopManuals.co.uk

Steering

Basic System Operation

Section H

3 — 1

2 Wheel Steer Machines

Steer System Schematics

Component Key:

6

7

10

42

43

P1

P2

P2A

S

T

44

Pump, Main Section

Pump, Secondary Section

Pressure Test Point

Suction Line

Tank

In-tank Filter

Priority Valve

Front Power Track Rod Ram

Steer Unit

Shock Valve

Steer Unit Relief Valve

Note:

Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on the actual component.

9803/3280

6

T

43

(L) (R)

S

P2 P1

42

(P)

(CF) (EF)

(LS)

44

(T)

P2A

(P)

7

(LS)

A263860

Purchased from www.WorkshopManuals.co.uk

10

Issue 1

Section H

3 — 2

www.WorkshopManuals.co.uk

Steering

Basic System Operation

Section H

3 — 2

2 Wheel Steer Machines

Hydraulic Operation

The main components of the steering system are the priority valve

7

, load sensing steer unit

42

, hydraulic tank

T

and the front power track rod ram

10

.

When the steering wheel is turned, a pressure demand is sensed at the priority valve

7

via load sensing line

LS

.

Oil from the hydraulic pump

P2

is then distributed via the priority valve to the steer unit

42

, which then directs the oil to the front power track rod ram

10

untill the required steering lock is achieved.

When the steering lock is held, the pressure signal

LS

ceases, flow from the hydraulic pump

P2

is now distributed to the main hydraulic circuit via the priority valve

7

.

Maximum steering system pressure is controlled by a relief valve located in the steering unit

42

.

7

10

P2

LS

7

42

T

42

9803/3280

A401110

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

3 — 3

www.WorkshopManuals.co.uk

Steering

Basic System Operation

Section H

3 — 3

4 Wheel Steer Machines

Steer System Schematics

Component Key:

11

42

43

44

7

8

T

6

10

P1

P2

P2A

S

Pump, Main Section

Pump, Secondary Section

Pressure Test Point

Suction Line

Tank

In-tank Filter

Priority Valve

Steer Mode Control Valve

Front Power Track Rod Ram

Rear Power Track Rod Ram

Steer Unit

Shock Valve

Steer Unit Relief Valve

Note:

Hydraulic component port identification letters are shown in parenthesis, e.g. (LS). The same letters will be stamped on the actual component.

9803/3280

6

T

43

(L)

(R)

S

P2 P1

42

(P)

(CF) (EF)

(LS)

P2A

(P)

7

44

(T)

(LS)

(T)

(P)

10

11

(B)

(A)

A263850

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

3 — 4

www.WorkshopManuals.co.uk

Steering

Basic System Operation

Section H

3 — 4

4 Wheel Steer Machines

Hydraulic Operation

The main components of the steering system are the priority valve

7

, load sensing steer unit

42

, hydraulic tank

T

, front power track rod ram

10

and rear power track rod ram

11

.

When the steering wheel is turned, a pressure demand is sensed at the priority valve

7

via load sensing line

LS

.

Oil from the hydraulic pump

P2

is then distributed via the priority valve to the steer unit

42

.

When left turn is selected, oil is distributed from steer unit

42

to the rear power track rod ram

11

via the steer mode control valve

8

. When right turn is selected, oil is delivered directly to the front power track rod ram

10

.

When the steering lock is held, the pressure signal

LS

ceases, flow from the hydraulic pump is now distributed to the main hydraulic circuit via the priority valve

7

.

Maximum steering system pressure is controlled by a relief valve located in the steering unit

42

.

A396570

8

7

P2

LS

7

42

8

T

11

10

42

9803/3280

A401120

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

3 — 5

www.WorkshopManuals.co.uk

Steering

Basic System Operation

Section H

3 — 5

4 Wheel Steer Machines

Electrical Operation

Three steering modes are available:

— 2 Wheel Steer (front axle)

— 4 Wheel Steer

— Crab Steer

The three modes are selected in the cab from a three position switch

A

which operates relays in the steer mode control unit

B

. The relays switch the energising supplies to the solenoid operated steer mode control valve

C

. Proximity switches on the front

D

and rear

E

axles signal when the wheels are in the straight ahead position.

Lights

L1

,

L2

or

L3

on the instrument panel illuminate to indicate the steer mode currently operative.

In 2 wheel steer mode only the front wheels are steered. In 4 wheel steer mode both axles are steered, giving a smaller turning circle and so improving manoeuvrability. The crab steer mode allows the machine to be driven diagonally into loading/unloading positions which might otherwise be inaccessible.

The system is prevented from changing mode until the relevant proximity switch is energised. If, for example, the system is set in 4 wheel steer and 2 wheel steer is then selected, the system will stay in 4 wheel steer untill the rear wheels are turned to the straight ahead position, thus energising the rear axle proximity switch. The rear wheels are then hydraulically locked in the straight ahead position.

D

E

A

C

B

L1

L2

L3

A401140

C

A

E

B

D

9803/3280

A401130

Purchased from www.WorkshopManuals.co.uk

Issue 1

www.WorkshopManuals.co.uk

Steer Unit Operation

— 2 Wheel Steer Machines

On 2 wheel steer machines the hydraulic steer unit operation is identical to that described for the 4 wheel steer machines, except the unit pumps oil out directly to a power track rod ram fitted on the front axle only. Also, therefore the 2 wheel steer machines do not have a steer mode control valve.

Refer to,

Steer Unit Operation — 4 Wheel Steer

Machines

.

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

4 Wheel Steer Mode

— Neutral

Flow from the priority valve enters the steering unit through the bottom right hand port past the nonret urn valve

43C

. When t he st eering w heel is stationary the inner spool

A

and sleeve

B

are held in the neutral position by the centring springs

K

. As the unit is ‘closed centre’ the flow from the pump is dead ended by the steering unit.

In 4 wheel steer mode the spools of the steer mode control valve

X

are configured as shown.

Component Key:

A

Inner Spool

B

Sleeve

D

Stator

K

Centring Springs

X

Steer Mode Control Valve

43C

Non-Return Valve

A395730

Purchased from www.WorkshopManuals.co.uk

43C

A

B www.WorkshopManuals.co.uk

K

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

B

X

D

Purchased from www.WorkshopManuals.co.uk

A395640

43B

LS

B

A www.WorkshopManuals.co.uk

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

40

41

B

X

D

A395650

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

4 Wheel Steer Mode

— Left Turn

The illustration shows the flow through the steering unit in a left hand t urn c ond it ion. Turning t he steering wheel rotates the inner spool

A

a few degrees relative to the outer spool

B

, and sends a pressure signal to the relief valve

43B

and through the

LS

port back to the priority valve.

The relative movement between

A

and

B

directs pressure oil through 6 of the 12 holes in the bottom of sleeve

B

. The metering unit is linked to the spools by a cross pin. As the steering is operated the oil is diverted by inner spool

A

into the stator

D

.

The rotor lobes pump the oil out to one side of the rear power track rod ram

41

turning the rear wheels to the right. At the same time pressurised oil from the other side of the power track rod ram

41

is fed to the front power track rod ram

40

, hence turning the front wheels the required degree of left turn.

Component Key:

A

Inner Spool

B

Outer Spool

D

Stator

LS

Load Sensing Port

X

Steer Mode Control Valve

40

Front Power Track Rod Ram

41

Rear Power Track Rod Ram

43B

Relief Valve

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

4 Wheel Steer Mode

— Right Turn

The illustration shows the flow through the steering unit in a right hand turn condition. The operation is identical to that described for a left hand turn, except that the oil is diverted by spool

A

to the other side of stator

D

and power track rod rams

40

and

41

.

Component Key:

A

Inner Spool

B

Outer Spool

D

Stator

LS

Load Sensing Port

X

Steer Mode Control Valve

40

Front Power Track Rod Ram

41

Rear Power Track Rod Ram

43B

Relief Valve

43C

Non-Return Valve

Purchased from www.WorkshopManuals.co.uk

43B

LS

43C

A

B www.WorkshopManuals.co.uk

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

40

41

B

X

D

A395660

Purchased from www.WorkshopManuals.co.uk

F

A

B www.WorkshopManuals.co.uk

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

40

A390630

41

B

X

D

A395670

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

4 Wheel Steer Mode

— Right Turn, Unassisted

The illustration shows the circuit operation with the engine stopped. Turning the steering wheel rotates the inner spool

A

until the cross pin engages with and rotates outer sleeve

B

, metering oil to the stator

D

, and pumping it out to power track rod rams

40

and

41

under manual pressure only.

As there is no supply from the pump, oil from one side of the power track rod rams, supplemented by exhaust oil if necessary, is used to feed the other side via non-return valve

F

.

Component Key:

A

Inner Spool

B

Outer Spool

D

Stator

F

Non-Return Valve

X

Steer Mode Control Valve

40

Front Power Track Rod Ram

41

Rear Power Track Rod Ram

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

4 Wheel Steer Mode

— Shock Valve

In normal operation oil flow from the pump enters the steering unit via the right hand port, opening a spring-loaded non-return valve

43C.

The flow is directed by the steering unit to achieve the desired turn (right hand shown).

In t he event of a p ressure shoc k w ave b eing generated in the system by an outside force, shock valve

43A

vents this pressure to exhaust preventing damage to the steering unit.

Non- return valve

J2

is held on its seat by the generated pressure and non- return valve

43C

closes to prevent the shock wave being fed back to the pump. Some of the excess flows via non-return valve

J1

to the opposite side of the power track rod ram to prevent cavitation occuring.

Component Key:

A

Inner Spool

B

Outer Spool

D

Stator

X

Steer Mode Control Valve

J1

Non-Return Valve

J2

Non-Return Valve

43A

Shock Valve

43C

Non-Return Valve

Purchased from www.WorkshopManuals.co.uk

43C

A www.WorkshopManuals.co.uk

B

J1

J2

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

B

43A

D

Purchased from www.WorkshopManuals.co.uk

X

A395680

43B

LS

43C

A

B www.WorkshopManuals.co.uk

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

40

41

B

X

D

A395700

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

2 Wheel Steer Mode

— Right Turn

The illustration shows the flow through the steering unit in a right hand turn condition. The operation is identical to that described for the 4 wheel steer mod e, exc ep t t he st eer mod e c ont rol valve

X

iscolates the oil flow to the rear power track rod ram

41

, consiquently the rotor lobes pump oil out to the front power track rod only. The rear wheels are held in the straight ahead position by the locked-up oil in the rear power track rod ram.

In 2 wheel steer mode the spools of the steer mode control valve

X

are configured as shown.

Component Key:

A

Inner Spool

B

Outer Spool

D

Stator

LS

Load Sensing Port

X

Steer Mode Control Valve

40

Front Power Track Rod Ram

41

Rear Power Track Rod Ram

43B

Relief Valve

43C

Non-Return Valve

A395740

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Steer Unit Operation

— 4 Wheel Steer Machines

Crab Steer Mode

— Right Turn

The illustration shows the flow through the steering unit in a right hand turn condition. The operation is identical to that described for the 4 wheel steer mod e, exc ep t t he st eer mod e c ont rol valve

X

directs the pressurised oil from the front power track rod ram

40

to the other side of the rear power track rod ram

41

, hence turning the rear wheels in the same direction as the front wheels, causing the machine to crab to the right.

In crab steer mode the spools of the steer mode control valve

X

are configured as shown.

Component Key:

A

Inner Spool

B

Outer Spool

D

Stator

LS

Load Sensing Port

X

Steer Mode Control Valve

40

Front Power Track Rod Ram

41

Rear Power Track Rod Ram

43B

Relief Valve

43C

Non-Return Valve

A395750

Purchased from www.WorkshopManuals.co.uk

43B

LS

43C

A

B www.WorkshopManuals.co.uk

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

40

41

B

X

D

A395690

Purchased from www.WorkshopManuals.co.uk

43B

T

LS

3 www.WorkshopManuals.co.uk

EF

2

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

LS

2A

R-CF

2C

2B

T

43B

P

43

LS

Purchased from www.WorkshopManuals.co.uk

A395710

www.WorkshopManuals.co.uk

Priority Valve Operation 1

— Neutral

When the steering is not being operated, flow to the steering circuit is dead ended by the closed centre steering unit

43

and no load is sensed in line

LS

.

Pressure from the main pump to the priority valve is fed via a drilling

2C

to the rear of spool

2B.

The high pressure differential created across the spool causes it to move to the left against the force of the spring

2A

. This allows full pump flow to the loader control valve

3.

Component Key:

LS

Load Sensing Port

P

From pump

T

To Loader Valve

2

Priority Valve

2A

Spring

2B

Spool

2C

Drilling

3

Loader Valve

43

Steer Unit

43B

Relief Valve

Purchased from www.WorkshopManuals.co.uk

www.WorkshopManuals.co.uk

Priority Valve Operation 2

— Turning

As the steering unit

43

is operated, pressure is applied to the spring end of the priority valve spool

2B

via sensing line

LS

from the steering unit.

This reduces the pressure differential across the spool, causing it to move to the right under spring force. This allows priority valve flow to the steering unit which directs the flow to the power track rod rams

40

and

41

untill the required steering lock is reac hed . When t he st eering lo c k is held t he pressure signal across the side port

LS

of the st eering unit c eases, rest o ring t he p ressure differential across spool

2B

. The spool moves back to the left, allowing full pump flow to the loader control valve

3

.

Because the pump output is always greater than the flow required to operate the steering system, flow to the loader valve is never completely cut off.

Maximum steering system pressure is controlled by relief valve

43B

, located in the steering unit

43

.

Component Key:

LS

Load Sensing Port

P

From pump

T

To Loader Valve

2

Priority Valve

2A

Spring

2B

Spool

2C

Drilling

3

Loader Valve

40

Front Power Track Rod Ram

41

Rear Power Track Rod Ram

43

Steer Unit

43B

Relief Valve

Purchased from www.WorkshopManuals.co.uk

43B

T

LS

3 www.WorkshopManuals.co.uk

2

Key to Oil Flow & Pressure

Full Pressure

Pressure

Servo

Neutral

Exhaust

Cavitation

Lock Up

A390630

EF

LS

2A

R-CF

2C

2B

T

43B

LS

P

43

Purchased from www.WorkshopManuals.co.uk

A395720

Section H

10 — 1

www.WorkshopManuals.co.uk

Steering

Fault Finding

Section H

10 — 1

Fault Finding Contents

Introduction

Steering wheel difficult to turn

Steering wheel turns on its own

Machine will not turn when the steering wheel turned.

Steering fails to respond to selected mode (4WS Machines only)

Page No.

10 — 1

10 — 1

10 — 2

10 — 2

10 — 3

Introduction

The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the steering section.

To help identify circuits, valves, rams etc mentioned in the fault finding procedures, refer to the hydraulic schematic diagrams (near the beginning of the Hydraulics Section).

1

Before you begin fault finding, read the Safety information at the beginning of this manual.

2

Make simple checks before say, stripping a major component.

3

Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

4

What ever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

5

Make any relevant electrical checks before moving on to the hydraulics.

6

Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the circuit.

7

Replace any seals such as ‘O’ rings before reassembling hydraulic components.

Fault

1

Steering wheel difficult to turn.

Probable Cause

Tyres not inflated to correct pressure

Insufficient hydraulic fluid.

Leaks in the relevant hoses or component connections

Air in the hydraulic system.

Low pump flow.

Steer relief valve set incorrectly

Worn or damaged parts in the steer control valve.

Action

Inflate tyres to correct pressure

Check for leaks and top up the hydraulic tank as required.

Check hoses and connections for leaks

Bleed system — bleed the load sense line.

Check pump flow, if required service or replace pump.

Check pressure setting of steer unit relief valve, adjust as required.

Remove and inspect.

……. continued

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

10 — 2

www.WorkshopManuals.co.uk

Steering

Fault Finding

Section H

10 — 2

Fault Probable Cause Action

1

Steering wheel difficult to turn.

(continued)

Priority valve not operating correctly

2

Steering wheel turns on its own.

3

Machine will not turn when the steering wheel turned.

Steer mode valve not operating correctly (4WS Machines only)

Mechanical failure

Dirt in the steer control unit

(causing sleeves to stick open)

Steer control valve centring springs damaged, broken or missing.

Steer control valve — position of rotor to shaft slot incorrect.

Insufficient hydraulic fluid.

Leaks in the relevant hoses or component connections

Air in the hydraulic system.

Low pump flow.

Steer relief valve set incorrectly

Worn or damaged parts in the steer control valve.

Check if the priority valve is st ic k ing , rec t if y as required.

Check the load sense line from the steer unit to the priority valve for signs of leak ing o r p o o r connection.

Check if spools sticking, rectify as required

Chec k if so leno id s o p erat ing , rep lac e solenoids as required

Check for damaged axle c o m p o nent s, suc h as rams, trackrods, linkages etc.

Clean and inspect unit.

Check steer unit.

Refer to

Hydraulic Steer

Unit — Dismantling and

Assembly

.

Correct as required.

Check for leaks and top up the hydraulic tank as required.

Check hoses and connections for leaks

Bleed system — bleed the load sense line.

Chec k p um p f lo w , if req uired servic e o r replace pump.

Check pressure setting of steer unit relief valve, adjust as required.

Remove and inspect.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

10 — 3

www.WorkshopManuals.co.uk

Steering

Fault Finding

Section H

10 — 3

Fault Probable Cause Action

3

Machine will not turn when the steering wheel turned (continued).

Priority valve not operating correctly

Steer mode valve not operating correctly (4WS Machines only)

Mechanical failure

Steer column splined shaft not fully engaged in steer valve.

Power track rod failure

Check if the priority valve is st ic k ing , rec t if y as required.

Check the load sense line from the steer unit to the priority valve for signs of leak ing o r p o o r connection.

Check if spools sticking, rectify as required

Chec k if so leno id s o p erat ing , rep lac e solenoids as required

Check for damaged axle c o m p o nent s, suc h as rams, trackrods, linkages etc.

Check shaft engagement.

Check power track rod for signs of damge, leaks etc.

4

Steering fails to respond to selected mode (4WS Machines only)

Selector switch faulty

Proximity switches not operating correctly

Steer mode valve not operating correctly

Leaks in the relevant hoses or component connections

Electrical failure

Check selector switch, replace as required

Check setting of

Proximity switches, reset or replace switches as required.

Check if spools sticking, rectify as required

Chec k if so leno id s o p erat ing , rep lac e solenoids as required.

Check hoses and connections for leaks

Check relevant electrical c onnec t ors, if p rob lem still persists, do a wiring c o nt inuit y c hec k o n relevant circuits.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

20 — 1

www.WorkshopManuals.co.uk

Steering

Service Procedures

Section H

20 — 1

Steering System — Bleeding

Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows.

With the engine running, the following procedure must be carried out in the correct order that is laid down. You must not alter the order of selections and operations.

1 Select 2 Wheel Steer

(a) Turn steering wheel to left, until front wheels are fully locked to the left.

(b) Turn steering wheel to right, until front wheels are fully locked to the right.

2 Select 4 Wheel Steer

(a) Turn steering wheel to left, until front wheels are fully locked to the left.

3 Select 2 Wheel Steer

(a) Turn steering wheel to full right lock.

(b) Turn steering wheel to full left lock.

(c) Turn steering wheel to full right lock.

4 Select 4 Wheel Steer

(a) Turn steering wheel to left, until the front wheels are fully locked to the left.

5 Select 2 Wheel Steer

(a) Turn steering wheel to full right lock.

(b) Turn steering wheel to full left lock.

(c) Turn steering wheel to full right lock.

6 Select 4 Wheel Steer

(a) Turn steering wheel to left, until front wheels are fully locked to the left.

7 Select 2 Wheel Steer

(a) Turn steering wheel to full right lock.

(b) Turn steering wheel to full left lock.

(c) Turn steering wheel to full right lock.

8 Select 4 Wheel Steer

(a) Turn steering wheel to left, until the front and rear wheels are fully locked.

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

20 — 2

www.WorkshopManuals.co.uk

Steering

Service Procedures

Section H

20 — 2

Steering System — Pressure Testing

1

Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Turn the steering wheel to the left and to the right several times to vent system pressure.

!

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

3

Connect a 0-400 bar (0-6000 lbf/in 2 ) pressure gauge to test adaptor

A

.

Note:

The pressure test point for the steering circuit is fitted next to the priority valve as shown.

4

Run the engine at 1500 revs/min and turn the steering to full lock. Check the gauge reading which should equal the relief valve pressure, refer to

Technical Data

.

Note:

The steering wheel must be held on full lock whilst the gauge reading is being checked.

5

If necessary, adjust the pressure setting by removing plug

B

, on the hydraulic steer unit.

6

Adjust screw

C

using an ‘ allen key’ until the correct pressure is shown on the gauge.

Note:

Detail

X

shows a relief valve which has a 4 mm hexagon adjusting screw. Detail

Y

shows a valve which has a 6 mm hexagon adjusting screw.

7

Refit plug

B

.

C

X

B

Y

S212750

A

9803/3280

S263940

Purchased from www.WorkshopManuals.co.uk

A390590

Issue 1

Section H

20 — 3

www.WorkshopManuals.co.uk

Steering

Service Procedures

Section H

20 — 3

Proximity Switch — Setting

!

WARNING

Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

GEN 3-2

Note:

The proximity switch setting procedure is the same for both the front and rear axles. The illustration shows a typical rear axle.

1

Align the wheels in the straight ahead position. Check if straight ahead by measuring the steering ram position.

Set the steering so that dimension

X

is equal both sides.

2

Remove the proximity switch cover

C

.

3

With the starter switch on, loosen the proximity switch lock nut

D

and slide the switch in line with the target disc

A

.

4

Loosen the bracket fixing bolts

E

and adjust the assembly up or down to bring the switch to the centre of the target disc. Tighten the fixing bolts

E

.

Make sure the light emitting diode (L.E.D.) is not illuminated (if it is then screw the switch out).

Now screw the proximity switch towards the target disc until the light emitting diode (L.E.D.) on the switch illuminates. Add a further 1 to 1.5 turns of the locknut.

Tighten the locknut.

E

D

A

E

C

Y

A

B

A258170

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

20 — 4

www.WorkshopManuals.co.uk

Steering

Service Procedures

Section H

20 — 4

Steer Mode Valve

— Checking Solenoid Operation

The solenoids operate according to the steer mode that is selected.

Mode:

2 Wheel Steer

4 Wheel Steer

Crab Steer

Solenoid(s) Energised:

W

X

,

Z

X

,

Y

Operation (energisation) of a solenoid can be easily detected by placing a steel object (e.g. screwdriver blade) close to the outer casing. A magnetic attraction of the steel object towards the solenoid indicates energisation.

If a solenoid is not energising carryout the following checks:

1

Check the fuse is intact. If not, renew and then check that all steer mode solenoid combinations function correctly.

2

If the fuse is intact remove the electrical connector from the malfunctioning solenoid(s) and check that the 12V supply is present across the connector pins. If not, check the supply circuit.

3

Check the solenoid coil resistance which should measure a few ohms (if unsure of the value compare with a known good solenoid).

Renew the solenoid if the reading indicates a short circuit (zero ohms) or open circuit (infinate resistance). If a reading somewhere between the two is obtained, reverse the two instrument probes and repeat for a valid check.

W X

9803/3280

Y

Z

A396570

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

20 — 5

www.WorkshopManuals.co.uk

Steering

Service Procedures

Section H

20 — 5

Priority Valve — Cleaning

The priority valve spool and spring may be removed for cleaning.

1

Remove the priority valve from the machine. Refer to

Priority Valve — Removal and Replacement

.

2

Unscrew adaptor

9

and extract the priority valve spring

11

.

3

Remove the blanking plug

7

. Press out the priority valve spool

12

using a nylon pin. Take care not to damage the bore of the valve.

4

Clean these components in clean paraffin paying particular attention to the orifices at each end of the spool. Dry off and lubricate with clean hydraulic fluid.

5

Refit the priority valve spool

12

making sure that the spring seat end of the spool faces towards the

LS

port.

Refit blanking plug

7

and torque tighten.

6

Refit the priority valve spring

11

and adaptor

9

and torque tighten.

7

Refit the valve onto the machine. Refer to

Priority

Valve — Removal and Replacement

.

8

Bleed the load sensing line. Refer to

Priority Valve —

Bleeding

.

9

10

11

3

4

Torque Settings

Item

7

9

Nm

50

50

Ibf ft

37

37

2

1

6

5

12

8

7

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

20 — 6

www.WorkshopManuals.co.uk

Steering

Service Procedures

Section H

20 — 6

Priority Valve — Standby Pressure Testing

1

Disconnect hose

A

and install a 0 — 40 bar (0 — 580 lbf/in 2 ) pressure test gauge into the valve port. Position the open end of hose

A

into a clean container in order to collect any oil drainage.

2

Disconnect hose

B

from load sensing port adaptor

C

and blank off.

3

Set the steering to neutral, i.e. do not turn the steering wheel, and start the engine. Gradually increase the engine speed to 1000 rev/min while checking the maximum pressure gauge reading which should be 5.9

to 8.7 bar (86 to 126 lbf/in 2 )

If the pressure is outside the limits try cleaning the priority valve, refer to

Priority Valve — Cleaning

.

If cleaning the valve does not rectify, check the hydraulic pump flow rate, refer to Section E

Main Pump — Flow and

Pressure Testing

.

If the hydraulic pump flow and pressure tests are satisfactory, then the priority valve must be renewed.

B

C

A

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

30 — 1

www.WorkshopManuals.co.uk

Steering

Power Track Rod

Section H

30 — 1

Removal and Replacement

This procedure is for a typical power steering track rod 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

!

WARNING

Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.

GEN-3-2

Removal

1

Disconnect and cap hydraulic hoses to prevent loss of fluid and ingress of dirt. Label hoses for identification and correct refitting.

2

On 4WD machines remove the split pin and nut

A

.

Remove the track rod ball joint from the wheel hub assembly.

On 2WD machines, remove lock assembly

B

and pin

C

to remove the track rod pivot from the wheel hub assemblies.

3

Remove the four fixing bolts

D

.

Replacement

1

Replace the power track rod by reversing the removal procedure. On 4WD machines make sure that the split pin is fitted.

2

After connecting hoses check hydraulic fluid level, if necessary top up.

3

Bleed hydraulic steering system, refer to

Service

Procedures, Steering System — Bleeding

.

Torque Settings

Nm Item

A

D

620

kgf m lbf ft

63 457

B

C

A

D

A258510

A258490

D

D

D

A258500

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

31 — 1

www.WorkshopManuals.co.uk

Steering

Power Track Rod

Section H

31 — 1

Link Arms — Removal and Replacement

L

M

A258480

A

J

F E

B

H

K

J

G

F

E

A258470

X

C

N

M

C

S300370

9803/3280

Y

Purchased from www.WorkshopManuals.co.uk

S258450

Issue 1

Section H

31 — 2

www.WorkshopManuals.co.uk

Steering

Power Track Rod

Section H

31 — 2

Link Arms — Removal and Replacement

Removal

1

Fix the assembly on a locally made strip/rebuild bench as shown.

2

Using two suitable open ended spanners at

L

and

M

react against each other until one ball joint unscrews.

3

Unscrew the ball joint

L

until an open ended spanner can be fitted on the rod

N

. Screw the ball joint against the spanner to secure the spanner and to prevent damage to the rod.

4

6

By reacting against the spanner at other ball joint.

the rod diameter with pipe grips etc.

assembly.

N

and

Where applicable remove the target disc

G

.

M

Note 1:

Flats at ‘E’ are:

2 Wheel drive machines — 32 mm A/F x 4 mm wide.

4 Wheel drive machines — 40 mm A/F x 4 mm wide.

undo the

Note 2:

The piston rod operates at full length, any damage to the surface will cause fluid leaks. DO NOT attempt to grip

5

Repeat the procedure for the remaining link arm

Note 3:

If the inner or outer ball joints need to be renewed, then a replacement link arm assembly must be fitted.

Replacement

Replacement is the reverse of removal but note the following:

1

Remember to fit the target disc

G

(where applicable).

2

Use JCB Threadlocker & Sealer on the trackrod link arms.

3

If the link arms have been renewed, the wheel alignment must be checked as follows:

a

Set the wheels to the straight ahead position and measure dimensions

X

and

Y

(at the outer edge of the wheel hub). Alignment is correct if the difference between

X

and

Y

is a maximum of 1 mm.

b

To adjust the wheel alignment undo the lock nuts

(

H

or

K

as applicable). Turn the threaded adjusters

J

equally to obtain the correct alignment. Tighten the lock nuts (

H

or

K

as applicable).

Note 4:

AWS machines shown at

A

. 2 wheel steer machines shown at

B

.

4

Check the proximity switch setting (where applicable).

Refer to

Service Procedures, Proximity Switch —

Setting

.

Torque Settings

2WS /4WD C

180 Nm (132 lbf ft)

2WS/4WD C

140/150 Nm (103/110 lbf ft)

AWS/4WD C

270/280 Nm (199/206 lbf ft)

AWS/4WD C

270/280 Nm (199/206 lbf ft)

2WS/2WD C

N/A

H

45/50 Nm (33/36 lbf ft)

K

300 Nm (221 lbf ft)

H

70/85 Nm (51/62 lbf ft)

K

390/410 Nm (287/302 lbf ft)

K

240/260 Nm (177/184 lbf ft)

E

240/260 Nm (177/184 lbf ft)

E

240/260 Nm (177/184 lbf ft)

E

450 Nm (331 lbf ft)

E

450 Nm (331 lbf ft)

E

240/260 Nm (177/184 lbf ft)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section H

32 — 1

www.WorkshopManuals.co.uk

Steering

Power Track Rod

Section H

32 — 1

Rams

Dismantling and Assembly

A

1

A258580

6

7

8

5

4

3

D

3

7

6

1

5

8

C

2

B

S258430

9803/3280

Purchased from www.WorkshopManuals.co.uk

A258590

Issue 1

Section H

32 — 2

www.WorkshopManuals.co.uk

Steering

Power Track Rod

Section H

32 — 2

Rams

Dismantling and Assembly

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Dismantling

1

Fix the ram assembly on a locally manufactured strip/rebuild bench as shown at

A

.

2

Remove both end caps, using a special spanner (refer to

Service Tools

). Pull the piston rod assembly from the cylinder.

Note 1:

DO NOT allow the piston rod to come into contact with the cylinder bore. The cylinder bore may be damaged by careless dismantling.

3

Position the piston rod assembly on a bench in place of the ram cylinder. Remove the seal and wear rings from the piston head.

Note 2:

The piston head cannot be removed from the rod. If there is damage to the rod or piston head, replace the complete assembly.

4

Carefully inspect the bore of the cylinder and the piston rod outer diameter for scoring, nicks and burrs. If such damage is visible the components must be renewed.

Note 3:

If burrs are evident on the ends of the piston rod at positions

C

or

D

remove by careful filing.

Both end cap assemblies are the same, dismantle as follows:

5

Remove the ‘O’ ring

5

, end cap seal

6

and wiper seal

7

.

6

The bearing bush

8

can be renewed if necessary.

However, time will be saved if a complete end cap and bush assembly is obtained.

Assembly

1

Clean the threads of the end caps and cylinder using a wire brush.

2

Use JCB Cleaner & Degreaser to ensure that all threads are free from grease, hydraulic oil and sealant.

Allow 15 minutes for solvent to dry before applying

JCB Threadlocker and Sealer (High Strength).

Ensure that lubricants used during assembly do not come into contact with the JCB Threadlocker and

Sealer (High Strength).

3

Refer to Section E

Rams — JCB Ram Sealing

Procedure

for the correct method of fitting seals to the end cap and piston head.

4

Clamp the cylinder vertically and lower the piston rod assembly in from the top, as shown at

B

. Take care not to allow the piston rod to come into contact with the cylinder bore. Be sure to engage the piston head new wear rings and seal carefully into the cylinder. If the piston head wear rings or seal are damaged during this stage, they must be renewed.

5

Apply JCB Activator to threads of the end caps and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the JCB Threadlocker and

Sealer (High Strength).

Note 4:

Neither the JCB Threadlocker and Sealer (High

Strength) nor Activator must be allowed to contact seals, bearing rings or ‘O’ rings.

6

Apply JCB Threadlocker and Sealer (High Strength) to threads of the ends caps, fit new ‘O’ ring

5

.

7

Ensure that there are no burrs at the ends of the piston rod, see

Dismantling — Note 3:

8

Fit an end cap over the piston rod. Apply light hand pressure to the cap to engage the gland seal on the piston rod. DO NOT use excessive force. Screw on the first end cap and then fix the assembly on the strip/rebuild bench as shown at

A

. Fit the remaining cap and then torque tighten both caps.

Note 5:

If hydraulic oil contacts the uncured JCB

Threadlocker and Sealer (High Strength) a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow a minimum of 2 hours between assembly and filling the ram with oil.

Torque Settings

Item

1

Nm

678

kgf m lbf ft

69.2

500

Note 6:

Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the track rod is operated slowly to its full extent in both directions before commencing normal working.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

40 — 1

www.WorkshopManuals.co.uk

Steering

Priority Valve

Section H

40 — 1

Removal and Replacement

!

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.

2-3-2-2

The priority valve is mounted on the right hand side chassis member, adjacent to the loader valve block. It is attached to the chassis member by one bolt

A

, and is accessible from underneath the machine.

When replacing always renew sealing ‘O’ rings

2

,

4

,

6

, and

10

.

9

Dismantling and Assembly

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Note 1:

The priority valve is not serviceable beyond the removal of foreign matter (Refer to

Service Procedures,

Priority Valve — Cleaning

). A faulty unit must be replaced.

Dismantling

Press out the spool item

12

using a nylon pin. Take care not to damage the bores of the valve.

Assembly

Make sure that spring seat of spool

12

faces toward

LS

connection.

Clean all parts in clean paraffin.

Lubricate all parts with hydraulic fluid.

Renew aluminium washers

8

and

10

.

Note 2:

All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

10

11

3

4

lbf ft

37

37

Bleeding

To bleed the

LS

line, start the engine, loosen the connection on the valve, turn and hold the steering wheel fully in either direction. When bubble free oil flows from the joint, tighten the connection.

2

1

5

6

12

8

7

A

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

45 — 1

www.WorkshopManuals.co.uk

Steering

Steer Mode Valve

Section H

45 — 1

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

!

DANGER

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

Removal

1

Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

2

Turn the steering wheel to the left and to the right several times to vent system pressure.

Note 1:

The steer mode valves assembly is fitted to a bracket which is mounted on the right hand side of the machine in front of the rear axle.

3

Disconnect the electrical solenoid connections. Label each connector before removal to ensure correct refitting. The wires should be identified

A

,

B

,

C

and

D

as shown.

4

Disconnect all hydraulic hoses from the steer mode valves assembly. Label the hoses to ensure correct refitting and cap the ends to prevent ingress of dirt.

5

Take hold of the steer mode valves assembly, loosen and remove bolts

E

. Lift the steer mode valves assembly and its retaining bracket from the machine.

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 immediately.

INT-3-1-10/1

Replacement is a reversal of the removal sequence.

1

Make sure that the electrical solenoid connections are refitted in the correct position.

2

Make sure that the hoses are correctly installed. The hose connections from the steer mode valves assembly are as follows:

P

— to hydraulic steer unit (L port)

B

— to rear power track rod (left side)

A

— to rear power track rod (right side)

T

— to front power track rod (right side)

Note 2:

The steer mode valves assembly ports should be stamped ‘ P’ , ‘ B’ , ‘ A’ and ‘ T’ . Left and right hand are as viewed from the rear of the machine.

3

Bleed the steering system, refer to

Service

Procedures, Steering System — Bleeding

.

A

C

B

D

E

E

A396570

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

45 — 2

www.WorkshopManuals.co.uk

Steering

Steer Mode Valve

Section H

45 — 2

Dismantling and Assembly

The numerical sequence shown on the illustration is intended as a guide to dismantling.

For assembly the sequence should be reversed.

Dismantling

1

Before dismantling scratch an alignment mark

X

along the faces of the solenoid valves and the manifold block.

Note 1:

Take care not to lose the detent balls

A

from items

16

and

18

.

Note 2:

The illustration depicts a complete strip down, but to carry out specific servicing/repairs, e.g. renewal of one of the solenoids

3

and

6

, it is only necessary to dismantle the relevant components.

Note 3:

None of the component parts of the CETOPS valve assembly can be renewed individualy. The extent of permissible servicing is cleaning and the consequential renewal of ‘O’ ring seals. If damage to any component or distortion of the spool is evident the complete valve assembly must be renewed.

Assembly

1

Renew all ‘O’ rings.

2

Lubricate parts with JCB Special Hydraulic fluid before assembling.

3

Use the alignment marks

X

(see

dismantling

) to ensure that the solenoids and the manifold block are assembled correctly.

Torque Settings

Item

1

Nm lbf in

7.1-9.1

63-80

1

2

4

3

9803/3280

15

18

17

A

A396550

16

8

9

11

10

19

13

12

14

6

7

5

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section H

50 — 1

www.WorkshopManuals.co.uk

Steering

Hydraulic Steer Unit

Section H

50 — 1

Removal and Replacement

Removal

!

DANGER

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

1

Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the at t ac hment s t o t he ground . St op t he engine and remove the starter key.

2

Turn the steering wheel to the left and to the right several times to vent system pressure.

3

Disc onnec t and c ap all hyd raulic hoses from t he steering unit as shown at

A

. Label the hoses to ensure correct refitting.

4

Get an assistant to hold the steering unit, and, working inside the cab, loosen and remove 4 bolts

B

. Lift the steering unit from the machine.

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 immediately.

INT-3-1-10/1

1

Replacement is a reversal of the removal sequence.

Make sure that the hoses are correctly installed.

2

B leed t he st eering syst em . Ref er t o

Se rvic e

Procedures, Steering System — Bleeding

.

3

If a new steering unit has been fitted then the system relief valve must be tested for correct pressure setting.

Refer to

Service Procedures, Steering System —

Pressure Testing

.

Note:

All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter.

A

B

9803/3280

Purchased from www.WorkshopManuals.co.uk

A390610

Issue 1

Section H

50 — 2

www.WorkshopManuals.co.uk

Steering

Hydraulic Steer Unit

Section H

50 — 2

9803/3280

Purchased from www.WorkshopManuals.co.uk

S10221A

Issue 1

Section H

50 — 3

www.WorkshopManuals.co.uk

Steering

Hydraulic Steer Unit

Section H

50 — 3

Dismantling and Assembly

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Note: 1

During manufacture, a small mark

X

will have been made on sleeve

12

and spool

15

, close to one of the slots for the centring springs

13

. Before removing the centring springs, check that this mark is visible; if not, make a new mark to ensure correct assembly.

Note: 2

Shock valves (items

29

to

35

) are pressure set during manufacture and the adjusting screw

31

secured with Loctite.

Due to the difficulty of resetting the pressure it is recommended that the valves are not disturbed. If dismantling is unavoidable, however, measure and record the depth of adjusting screw

31

below the top face of the steering unit before removing the screw.

Note: 3

The unit illustrated in the following sequence represents a typical hydraulic steer valve. The relief valve (items

25

to

28

) and shock valves (items

29

to

35

) are not therefore shown in the following illustrations.

Assembly

1

Fit spool

15

into sleeve

12

, aligning slots for centring springs

13

and checking that the small marks

X

are aligned . Ensure t hat t hree slot s in sp ool p art ially uncover three holes in sleeve, as at

A

.

2

Fit two flat centring springs

13

with four curved springs between them, as shown at

B

.

3

Fit seal

24

into steer unit body and insert sleeve of service tool 892/00180. Fit back up ring

20

and seal

21

onto plastic boss, and position on tool spindle, as shown.

4

Lower steering unit body and tool sleeve over tool spindle until plastic bush is flush with end of bore.

Assemble sleeves

12

and

15

with cross pin

14

and centring springs

13

. Fit bearing components

16

to

19

with chamfered face of

17

facing away from bearing

18

.

X

S229680

5

Remove body from tool leaving plastic bush in position, and lower body over assembled spool.

6

Apply downward pressure on body until plastic boss is forced out of bore, leaving seals correctly located.

9803/3280

Purchased from www.WorkshopManuals.co.uk

S229690

Issue 1

Section H

50 — 4

www.WorkshopManuals.co.uk

Steering

Hydraulic Steer Unit

Section H

50 — 4

Assembly (Continued)

7

Invert unit and place on a suitable hollow support so that body does not rest on protruding sleeve, thus preventing displacement of the new seals. Place ball

23

into check valve hole and fit bush

22

.

8

Fit new ‘O’ ring

10

.

9

Fit distributor plate

9

ensuring that holes align. Locate shaft

11

onto cross-pin

14

, noting position of slot.

When rotor

7

is fitted, slot must align with hollows of rotor as shown at

C

.

S229700

10

Use a suitable piece of rigid flat material, 0.25mm

(0.010 in.) thick, to support the shaft and ensure positive engagement with the splines of rotor

7

.

11

Locate rotor onto shaft, ensuring alignment as at

C

. Fit spacing bush

6

into rotor.

12

Fit ‘O’ rings

4

and

8

each side of body

5

, then position body over rotor.

13

Refit the end plate and fit at least one bolt

2

before removing support material.

14

Fit remaining bolts, ensuring that special bolt

1

is correctly located. Tighten all bolts to 29Nm (22 lbf ft).

S229710

Pressure Relief Valve Cartridge

After renewing the ‘ O’ ring, torque tighten the cartridge to 50 Nm (37 lbf ft). The relief valve is preset, refer to

Technical Data

for the valve setting. The relief valve setting should be rechecked after fitting the steering unit to the machine. Refer to

Service Procedures, Steer System — Pressure Testing

.

Shock Valves

If the shock valves have been dismantled, clean the threads of adjusting screw

31

and the threads in the bore of the steering unit body using JCB Cleaner/Degreaser, allow to dry. Assemble seat

35

, ball

34

, cap

33

and spring

32

then coat threads of screw

31

with JCB Threadlocker and Sealer. Assemble screw to depth measured during dismantling then fit plug

29

and washer

30

.

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk

i

Section K

www.WorkshopManuals.co.uk

Engine

Section K i

Contents

Service Tools

Technical Data

Service Procedures

Fuel Lift Pump

— Cleaning the Strainer

Engine

— Removal & Replacement

Page No.

1 — 1

2 — 1

20 — 1

30 — 1

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section K

1 — 1

www.WorkshopManuals.co.uk

Engine

Service Tools

Section K

1 — 1

892/00836

Lifting Wire Assembly (for engine removal)

S192390

892/00041 De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)

S219080

892/00936 Timing pin for fuel injection pump

(AK, AM, AR)

A314530

9803/3280

892/0104 Adaptor for compression testing

(AK, AM, AR)

For details of other engine service tools refer to Engine

Service Manual, Publication No. 9806/0100 or 9806/2140 for low emission engines.

Issue 1

Purchased from www.WorkshopManuals.co.uk

Section K

2 — 1

www.WorkshopManuals.co.uk

Engine

Technical Data

Section K

2 — 1

Type

Engine Build List Number

1000 Series 4 cylinder Engines

AB — Turbocharged

AA — Naturally Aspirated

AK — Turbocharged

AM — Turbocharged and Intercooled

AR — Naturally Aspirated

AA50608 — AR50656, AR50654, AR50678 — 56kw (75bhp), AK50745 60kw (80bhp)

AA50606 — 56kw (75bhp)

AB50607 — 67.5 kw (90.5bhp), AK50628 — 68.5 kw (92bhp)

AB50609 — 71.5kw (96bhp), AK50640 — 74.6 kw (100bhp) AM50647 85.5 kw (115bhp)

Bore

AA, AB, AK, AM

AR

Stroke

Swept Volume

Compression Ratio

100mm (3.937 in)

103mm (4.055 in)

127mm (5.000 in)

AB, AA, AK, AM

AR

AB

AA

4 litres (243 in 3 )

4.23 litres (258 in 3 )

16.0:1

16.5:1

Compression Pressure

AK, AM

AR

17.25:1

18.5:1

28 bar (400 lbf/in 2 )

[maximum variation between cylinders 3.5 bar (50 lbf/in 2 )]

1,3,4,2 Injection Sequence

Valve Clearance — Cold — Inlet

— Exhaust

Oil Pressure (hot) at maximum speed — AA

— AB, AK, AM

— AR

Maximum Air Cleaner Restriction

0.20mm (0.008 in)

0.45mm (0.018 in)

2.1 bar (30 lbf/in

2.6 bar (40 lbf/in

2.0 bar (30 lbf/in

559mm (22 in H 2

2

2 )

2 )

)

O)

Injection System Details — Refer to appropriate Engine Service Manual.

Idling Speed

Maximum Governed Speed

Maximum No-load Speed (High Idle)

— All builds

— All builds

— All builds

880 — 930 rev/min

2200 rev/min

2400 — 2440 rev/min

Cooling System

Coolant Pressure

Coolant Temperature (Normal)

Temperature Warning Light operates at:

0.48 bar (7 lbf/in

2

)

80-85 °C (176-185 °F)

98 °C (208 °F)

Note:

For further details of the engines refer to the following Engine Service Manuals:

Publication No. 9806/0100 (AA, AB)

Publication No. 9806/2140 (AK, AM, AR)

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section K

20 — 1

www.WorkshopManuals.co.uk

Engine

Service Procedures

Section K

20 — 1

Fuel Lift Pump

— Cleaning the Strainer

To remove and fit pump, see Engine Service Manual.

Remove and c lean fuel inlet st rainer

2

if b loc kage is suspected ie. low engine power, difficult to start, fuel tank contamination.

1

Allow the engine to cool. Remove the fuel filler cap to vent the system and reduce loss of fuel. Disconnect the fuel inlet pipe to the lift pump.

2

Unscrew the fuel filter

A

. Remove strainer

2

and O-ring

3

.

3

Clean the strainer in clean diesel fluid and dry with low pressure compressed air. Renew the strainer and Oring if damaged.

4

Fit the strainer into the fuel inlet connection. Fit the inlet connector

A

and tighten to 20Nm (15 lbf ft). Fit the fuel inlet pipe carefully to prevent damage to the strainer, and tighten the union nut.

IMPORTANT: The fuel strainer can be damaged and fuel flow can be restricted if the fuel pipe is inserted too far into the inlet connection. This should be checked if a fuel restriction is suspected.

Make sure the olive on the fuel inlet pipe is in good condition and forms an effective seal. Renew the olive or pipe if necessary to prevent air entering the fuel system.

5

Fit the tank cap and prime the fuel system. Start the engine and check for fuel leakage.

3

A

2

366610

9803/3280

Purchased from www.WorkshopManuals.co.uk

Issue 1

Section K

30 — 1

www.WorkshopManuals.co.uk

Engine

Engine

Section K

30 — 1

c

Q

Q

9803/3280

c

R

A a a b

S

S b

P

N

Purchased from www.WorkshopManuals.co.uk

A401530

Issue 1

Section K

30 — 2

www.WorkshopManuals.co.uk

Engine

Engine

Section K

30 — 2

Removal and Replacement

Removal

1

Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.

Chock the road wheels.

2

Raise the loader arms and fit the loader arm safety strut.

Note:

In the event of engine failure, the loader arms will have to be raised using suitable lifting equipment. Make sure that the loader control lever is in the ‘raise arms’ position before manually lifting the loader arms.

3

Remove the engine side panels

4

Remove the engine cover (including the exhaust stack).

5

Disc onnec t t he b at t ery. When d isc onnec t ing t he battery, take off the earth (black) lead first.

6

Remove retaining bolts and then lift off the front grille.

7

Remove retaining bolts

A

and

B

(both sides) and lift off the front nose guard.

8

Disconnect the hydraulic oil cooler hoses

C

from the hydraulic oil cooler. Plug and cap open ports to prevent ingress of dirt.

Note:

When installing and removing hoses from the cooler, it is essential to note that adaptor

D

must be held with a spanner whilst installing or removing the hose. It may be easier to remove the top hose connection once the cooler has been removed from the machine.

9

Drain the cooling system.

10

Remove the transmission oil cooler hoses

E

.

11

Remove the radiator top hose and bottom hose.

12

Remove the coolant bottle pipe.

13

M ake a suit ab le alignment mark t o allow c orrec t repositioning of the radiator shroud, as shown at

F

.

14

If an engine fan guard is fitted, remove retaining bolts and lift off the guard.

15

Remove retaining bolts

G

(both sides) and lift off the radiator sub-assembly including radiator, hydraulic and transmission coolers, and shroud. Take care not to d am ag e t he eng ine f an, no t e also t hat t he sub assembly is heavy, use suitable lifting equipment.

Note:

If required, the shroud, radiator and coolers can be removed as individual items.

16

Loosen and remove the exhaust silencer retaining bolts, remove the silencer.

17

Loosen and remove the retaining clamp for the heater hose. Remove the hose.

18

Loosen and remove the retaining clamp for the air filter intake hose.

19

Remove the air intake filter. Use tape to close the opening in the air intake manifold, this will prevent ingress of dirt.

20

Loosen and remove the brake master cylinder reservoir retaining bolts. Do not remove the pipes attached to the master cylinder reservoir but put the reservoir out of the way. Make sure that the fluid level does not drain down.

21

Lab el and remove all elec t ric al c onnec t ions, t he number of connectors will vary depending on the anc illary eq uip ment fit t ed t o t he engine. Typ ic al electrical connectors are: ii) alternator iii) coolant pressure switch iv) v) vi) coolant temperature sender engine oil pressure switch engine temperature sender vii) viii) ix) engine shut off solenoid ether cold start (if fitted) air conditioning compressor (if fitted)

22

If air conditioning is fitted:

Note:

The air conditioning is a pressurised closed loop system, do not disconnect the hoses to the compressor.

Leave the hoses to the compressor intact.

a

Rem o ve t he b elt f ro m t he c lut c h o f t he air conditioning compressor.

b

Disc o nnec t t he elec t ric al c o nnec t o rs at t he compressor.

c

Lo o sen and rem o ve t he air c o nd it io ning compressor retaining bolts.

d

Put the air conditioning compressor out of the way

(do not allow the compressor to ‘ hang’ on its hoses).

23

Loosen and disconnect the fuel lines

J

from the fuel sedimenter. Plug and cap open orifices to prevent ingress of dirt and loss of fuel.

24

Loosen and remove the retaining bolts for the fuel sedimenter, remove the sedimenter

K

.

……cont’d

Issue 1 9803/3280

Purchased from www.WorkshopManuals.co.uk

Section K

30 — 3

www.WorkshopManuals.co.uk

Engine

Engine

Section K

30 — 3

Removal and Replacement

Removal (continued)

25

If fitted, loosen and disconnect the ether cold start fuel line from the engine. Plug and cap open orifices to prevent ingress of dirt and loss of fluid.

26

If fitted, loosen and remove the ether cold start canister retaining bolts, lift off the canister and retaining bracket assembly

.

27

Disconnect the throttle linkage

L

from the arm on the fuel injection pump. Leave at least one of the locking nuts in position, this will ensure that the engine revs are set correctly when reassembling.

28

Loosen and remove the rear propshaft to gearbox retaining bolts

M

.

29

On 4WD mac hines, loosen and remove t he front propshaft to gearbox retaining bolts

N

.

30

Remove the access bung located at the base of the gearbox. Through the access hole, loosen and remove the torque converter to engine flywheel retaining bolts

P

(turn the flywheel to align bolts with access hole).

31

If manual gearbox fitted, disconnect the gearshift lever from the top of the gearbox.

32

Use a suitable trolley jack and support the weight of the gearbox.

Note:

Attach a ‘cradle’ to the trolley jack that will evenly support the weight of the gearbox. Refer to

Service Tools

.

33

Use a suitable stand and support the weight of the engine.

34

Loosen and remove the gearbox mounting bolts

Q

.

35

Remove the gearbox to engine retaining bolts

R

, pull the transmission and converter clear of the engine, make sure that the converter stays mounted on the gearbox shaft.

36

Attach suitable lifting chains to the engine (see Lifting

Wire Assembly, service tool 892/ 00836 in

Service

Tools

). Take the weight of the engine on the hoist.

37

Loosen and remove the engine mounting bolts

S

(both sides).

38

Lift the engine clear of the machine.

39

Put t he eng ine o n a suit ab le st and , t he c o rrec t dismantling and assembly procedures are detailed in t he Eng ine Servic e M anual, p ub lic at io n num b er

9806/0100.

Replacement

Replacement is a reversal of the removal procedure.

1

When mating the gearbox/torque converter to engine, ensure that the drive tangs are correctly located in the gearbox pump. See Section F

Gearbox Replacement

for a detailed procedure.

Note: It is vitally important that the torque converter is fitted at the gearbox and engine flywheel correctly.

Failure to locate the converter correctly will result in damage to the gearbox oil pump on engine start up.

2

When you are satisfied that the torque converter is located correctly, use the access hole in the bottom of the gearbox to fit and tighten the flexi-plate to engine flywheel retaining bolts. Rotate the flywheel to align the next bolt hole, fit and tighten all retaining bolts.

3

When fitting the radiator sub- assembly, including radiator, cooler and shroud take care not to damage the engine fan, align the shroud using alignment mark made at step 13 in

Removal

.

4

Make sure that the front nose guard and the engine cover are correctly aligned.

5

Ref ill c o o ling syst em using c o rrec t m ix t ure o f water/anti-freeze.

6

Check engine, coolant and brake oil levels.

7

When connecting the battery, connect the earth (black) lead last.

Make sure that the engine idle speed is correct, adjust as required, refer to

Technical Data

.

Torque Figures

Item Nm Kgf m lbf ft Description

M

118 12 87 Rear propshaft bolts

N

P

Q

R

S

79

44

237

98

85

8

4.5

24

10

8.7

58

32

175

72

63

Front propshaft bolts

Flexi-plate to flywheel bolts

Gearbox mounting bolts

Gearbox to engine bolts

Engine mounting bolts

Note

: The engine oil pressure switch, water temperature switch and water temperature sensor torque figure varies depending on the material it is screwed into.

Plastic

Nm

4

Aluminium 30

Kgf m

0.4

3.0

lbf ft

3.0

22

9803/3280 Issue 1

Purchased from www.WorkshopManuals.co.uk