13547289-J34222BLSRMID344T4349T92229O-Jcb_3cx_4cx_214_215_217_Backhoe_Loader_Service_Repair_Manual_Instant_Download_-_3cx_4cx_460001_To_499999_3cx_4cx_92000

General Information Care & Safety Routine Maintenance R

Attachments

Service Manual 3CX, 4CX, 214, 215, 217 & VARIANTS

Body & Framework Electrics Controls Hydraulics

Backhoe Loader From M/c No. 460001 To 499999 920001 On 900001 On (N.Am only) PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/3270 & 9803/3270U

Transmission Brakes Steering Engine

1 2 3 A B C D E F G H K

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: 1 2 3 machine.

= = =

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. 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. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

9803/3270

Issue 1 SXXXXXX

SXXXXXX

SXXXXXX

Section 1

General Information

Section 1

i

i

Contents Machine Identification Plate

1-1

Typical Vehicle Identification Number (VIN)

1-1

Typical Engine Identification Number

1-1

Serial Plates

1-2

Torque Settings

2-1

Service Tools Numerical List

3-1

Service Tools - Body & Framework - Electrics - Hydraulics - Transmission - Engine Sealing and Retaining Compounds

9803/3270

Page No.

4-1 4-4 4-6 4 - 10 4 - 17 5-1

Issue 2

Section 1

General Information

Section 1

1-1

1-1

Machine Identification Plate

Typical Vehicle Identification Number (VIN)

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.

SLP

3CX

T

S

V

E

0460001

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: R = 1994 S = 1995 T = 1996 V = 1997 W = 1998 X = 1999 Y = 2000

1 = 2001 2 = 2002 3 = 2003 4 = 2004 5 = 2005 6 = 2006 7 = 2007

F Manufacturer Location (E = England) G Product Identification Number (PIN) S218131

U.K. and R.O.W. Typical Engine Identification Number AB

50262

U

500405

P

B

C

D

E

A

A Engine Type AB = 4 cylinder turbo B Build Number C Country of Origin D Engine Sequence Number E Year of Manufacture

North America

9803/3270

A246740

Issue 1

Section 1

General Information

Section 1

1-2

1-2

Serial Plates A Front Axle (2WS machine)

D

B Front Axle (4WS machine) C Rear Axle (2WS machine) D Rear Axle (4WS machine) E Syncro Shuttle Transmission F Powershift Transmission

S259110

G Engine

E A S257580

S143031

F

B S259100

S146790

C G S156571

9803/3270

S260120

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General Information

Section 1

2-1

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)

Hexagon (A/F) in

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)

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 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m

lbf ft

1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

10 20 36 58 87 125 175 300 480 715 1430 2500

Torque Settings kgf m

lbf ft

Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

(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

0.7 1.2 3.0 5.7 10 25 48 84 166 291

5 9 21 42 72 180 352 607 1205 2105

Rivet Nut Bolts/Screws Bolt Size

M3 M4 M5 M6 M8 M10 M12

(mm)

Torque Settings (for steel rivet nuts) Nm kgf m lbf ft

(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.

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Section 1 3-1

Service Tools Numerical List Page No. 1406/0011 1406/0014 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1604/0008 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1606/0012 1606/0014 1606/0015 1606/0017 1612/0006 4101/0651 4101/0250 4101/0451 4102/0502 4102/0551 4102/0933 4102/1212 4102/1951 4102/2309 4103/2109 4104/0251 4104/0253 4104/1203 4104/1206 4104/1310 4104/1538 4201/4906 816/00017 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/00439 816/00440 816/15007 816/15008 816/15118 816/20008 816/20013 816/50005 816/50043 816/55038 816/55040 816/60096 825/00410 825/99833 826/01099 826/01101 826/01102 826/01103 826/01104 9803/3270

Bonded Washer Bonded Washer Bonded Washer Bonded Washer Bonded Washer Male Adapter Male Adapter Male Adapter Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Male Adapter Adapter Retainer (High Strength) Threadlocker and Sealer Threadlocker High Strength Gasketing High Strength Threadlocker Clear Silicone Sealant Multi-Gasket Threadseal Black Polyurethane Sealant Ultra Fast Adhesive (310ml) Activator (Aersol) Activator (Bottle) Active Wipe 205 (250g) Active Wipe 205 (30 ml) Hand Cleaner JCB Cleaner & Degreaser Black Primer 206J (30ml) Adapter Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Male Adapter Male Adapter Male Adapter Male Adapter Pressure Test Adapter Adapter Adapter Adapter Adapter Pressure Test 'T' Adapter Pressure Test 'T' Adapter Adapter Crowfoot Wrench Adapter for 825/00410 Rivet Nut Rivet Nut Rivet Nut Rivet Nut Rivet Nut

4-7 4-7 4-7 4 - 6, 4 - 7 4-7 4-7 4-7 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 4-6 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 4-1 5-1 5-1 4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-7 4-7 4-7 4-7 4-6 4-6 4-6 4-8 4-8 4-6 4-6 4-8 4-4 4-4 4-1 4-1 4-1 4-1 4-1

Page No. 826/01105 892/00011 892/00041 892/00047 892/00048 892/00049 892/00051 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 892/00071 892/00074 892/00075 892/00076 892/00077 892/00078 892/00137 892/00167 892/00174 892/00179 892/00180 892/00182 892/00223 892/00224 892/00225 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00273 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00282 892/00283 892/00284 892/00285 892/00286 892/00293 892/00294 892/00295 892/00298 892/00301

Rivet Nut 4-1 Spool Clamp 4-8 De-glazing Tool 4 - 17 Adapter 4-8 Adapter 4-8 Adapter 4-8 Adapter 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Blanking Plug 4-8 Male Adapter 4-7 Female Connector 4-8 Female Connector 4-8 Female Connector 4-8 Female Connector 4-8 Connector 4-6 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7 Ram Seal Protection Sleeve 90 mm 4 - 9 Measuring Cup 4 - 12 Bearing Press 4 - 10 Seal Fitting Tool 4-9 Bearing Pad Driver 4 - 12 Hand Pump 4-7 Impulse Extractor 4 - 11 Adapter for Extractor 4 - 11 Pressure Test Kit 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test Adapter 4-6 Pressure Test 'T' Adapter 4 - 6, 4 - 7 Pressure Test 'T' Adapter 4-6 Pressure Test 'T' Adapter 4-6 Pressure Test 'T' Adapter 4-6 Flow Monitoring Unit 4-6 Sensor Head 4-6 Load Valve 4-6 Adapter 4-6 Adapter 4-6 Sensor Head 4-6 Adapter 4-7 Adapter 4-6 Adapter 4-6 Adapter 4-6 Gauge 4-7 Gauge 4-7 Shunt 4-4 Tool Kit Case 4-4 Tachometer 4-4 Hydraulic Oil Temperature Probe 4-4 Surface Temperature Probe 4-4 Connector Pipe 4-6 Connector Pipe 4-6 End Float Setting Tool 4 - 10 Fluke Meter 4-4 Flow Test Adapter 4 - 10 Issue 3

Section 1

General Information

Section 1

3-2

3-2

Service Tools Numerical List Page No. 892/00302 892/00309 892/00333 892/00334 892/00335 892/00706 892/00812 892/00817 892/00818 892/00819 892/00822 892/00825 892/00836 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/00881 892/00882 892/00891 892/00916 892/00918 892/00920 892/00922 892/00940 892/00948 892/00949 * 892/00956 892/00964 892/00965 892/00966 * 892/01016 * 892/01017 * 892/01018 * 892/01019 * 892/01020 * 892/01021 * 892/01022 * 892/01023 * 892/01024 * 892/01025 * 892/01026 * 892/01027 921/52600 926/15500 990/00083 992/04000 992/04800 992/07608 992/07609 992/07610 992/07611 992/07612 992/07613 992/09100 992/09200 9803/3270

Flow Test Adapter 4 - 10 ARV Test Kit 4-7 Heavy Duty Socket 4 - 11 Gland Seal Fitting Tool 4-9 ARV Cartridge Removal Tool 4-7 Test Probe 4 - 6, 4 - 7 Drive Coupling Spanner 4 - 10 Heavy Duty Socket 4 - 11 Heavy Duty Socket 4 - 11 Heavy Duty Socket 4 - 11 Splined Bolt Socket 4 - 12 End Float Setting Tool 4 - 10 Lifting Wire Assembly 4 - 17 Glass Lifter 4-2 Folding Stand 4-1 Long Knife 4-3 Cartridge Gun 4-1 Glass Extractor (Handles) 4-2 Nylon Spatula 4-3 Wire Starter 4-2 Braided Cutting Wire 4-3 Spool Seal Fitting Tool 4-7 Alternator Pulley Socket 4-5 Wheel Hub Seal - Fitting Tool 4 - 11 Clutch Pack Spring Compressor 4 - 12 Setting Tool Kit 4 - 15 Flow Test Adapter 4 - 10 12.2” T/C Alignment Tool 4 - 10 Speed Sensor Test Lamp 4-4 Charging Kit 4-9 Pressure Gauge 4-9 Timing Pin 4 - 17 Test Point (1/8BSP) 4 - 15 Test Point (3/8BSP) 4 - 15 Test Point (1/4BSP 4 - 15 Ram Seal Protection Sleeve 25 mm 4-9 Ram Seal Protection Sleeve 30 mm 4-9 Ram Seal Protection Sleeve 40 mm 4-9 Ram Seal Protection Sleeve 50 mm 4-9 Ram Seal Protection Sleeve 50 mm 4-9 (slew ram) Ram Seal Protection Sleeve 60 mm 4-9 Ram Seal Protection Sleeve 60 mm 4-9 (slew ram) Ram Seal Protection Sleeve 65 mm 4-9 Ram Seal Protection Sleeve 70 mm 4-9 Ram Seal Protection Sleeve 75 mm 4-9 Ram Seal Protection Sleeve 80 mm 4-9 Piston Seal Assembly Tool 4-9 Spacer Kit 4 - 15 Rubber Spacer Blocks 4-3 End Float Setting Tool 4 - 10 Torque Multiplier 4 - 12 Flange Spanner 4 - 12 Bearing Adapter 4 - 10 Bearing Adapter 4 - 10 Bearing Adapter 4 - 10 Bearing Adapter 4 - 10 Bearing Adapter 4 - 10 Bearing Adapter 4 - 10 Spool Clamp 4-8 Charging Tool 4-1

Page No. 992/09300 992/09400 992/09500 992/09600 992/09700 992/09900 992/10000 992/12300 992/12400 992/12600 992/12800 992/12801 993/55700 993/59500 993/68100 993/69800 993/70100 993/70111 993/78200 993/85700 7210/0001 7210/0002 7210/0003 7212/0001 7212/0002 7212/0003 7212/0004 7213/0001 7213/0002 7213/0003 7213/0004 7213/0005 7213/0006 7213/0007 7213/0008 7214/0001 7214/0002 7214/0003 7214/0004 7216/0001 7216/0002 7216/0003 7216/0004 7218/0001 7218/0002 7218/0003 7218/0004 7219/0001 7219/0002 7219/0003 7219/0004 7219/0005 7219/0006 7219/0007 7219/0008

Ram Spanner Ram Spanner Ram Spanner Ram Spanner Ram Spanner Ram Spanner Ram Spanner 12V Mobile Oven Static Oven - 2 Cartridge Static Oven - 6 Cartridge Cut-Out Knife "L" Blades Direct Glazing Kit Impulse Extractor Adapter Slide Hammer Kit Seal Kit Powershift Endfloat Checking Kit Breakback Torque Wrench Mainshaft Airline Adapter Battery Tester Dummy Plug Wire Seal (1.4 - 2.2 mm dia.) Wire Seal (2.2 - 2.9 mm dia.) 2 Way Socket Connector 2 Way Pin Housing 2 Way Socket Retainer 2 Way Pin Retainer 3 Way Socket Connector 3 Way Pin Housing 3 Way Socket Retainer 3 Way Pin Retainer 3 Way Socket Connector (DT) 3 Way Pin Housing (DT) 3 Way Socket Retainer (DT) 3 Way Pin Retainer (DT) 4 Way Socket Connector 4 Way Pin Housing 4 Way Socket Retainer 4 Way Pin Retainer 6 Way Socket Connector 6 Way Pin Housing 6 Way Socket Retainer 6 Way Pin Retainer 8 Way Socket Connector 8 Way Pin Housing 8 Way Socket Retainer 8 Way Pin Retainer 10 Way Socket Connector 10 Way Pin Housing 10 Way Socket Retainer 10 Way Pin Retainer 14 Way Socket Connector 14 Way Pin Housing 14 Way Socket Retainer 14 Way Pin Retainer

4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-1 4-2 4-2 4-2 4-2 5-1 4 - 11 4-3 4-6 4 - 16 4 - 15 4 - 15 4-4 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 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 4-5 4-5 4-5 4-5 4-5

Issue 4*

Section 1

General Information

3-3

Section 1 3-3

Service Tools Numerical List 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

Page No. 4-9

Replacement items for kit no. 892/00253 892/00201 Replacement Gauge 892/00202 Replacement Gauge 892/00203 Replacement Gauge 892/00254 Replacement Hose

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 993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 993/68111 Adaptor - M20 x 1/2" UNF

4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3

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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

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part 892/00845

number

-

Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number - 4104/1310 (454g; 1 lb tub)

S186270

S186240

Folding Stand for Holding Glass essential for preparing new glass prior to installation. 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 892/00843

number

-

JCB part number - 992/12300 S186250

9803/3270

S186280

Issue 1

Section 1

General Information

Section 1

4-2

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.

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: 992/12400 - 2 Cartridge x 240V 992/12600 - 6 Cartridge x 240V

JCB part number - 892/00842

S186300

S186260

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

9803/3270

S186350

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General Information

Section 1

4-3

4-3

Service Tools (cont'd) Section B - Body & Framework Long Knife - used to give extended reach for normally inaccessible areas.

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

JCB part number - 892/00844 JCB part number - 892/00849 (approx 25 m length)

S186360

S186330

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

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

6 7 8 9 10 11

S186550

:993/68106 :993/68107 :993/68108 :993/68109 :993/68110 :993/68111 2

11

Adaptor - M20 x M24 Bar - M20 x M20 X 800MM Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x 5/8" UNF (Shoulder) Adaptor - M20 x 1/2" UNF 2 5

1

3

6

2

4

9 10 8 7

S196910

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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

5

892/00282

100 amp Shunt - open type

6

892/00285

Hydraulic Temperature Probe

Microtach

Digital

Tachometer

S188231

993/85700

Battery Tester

892/00882

Socket for Alternator Pulley Nut

S239510

825/00410 825/99833

*892/00940

15 mm Crowfoot Wrench Adapter

S216200

9803/3270

S216770

Speed Sensor Test Lamp

S298910

Issue 2*

Section 1

General Information

Section 1

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4-5

Service Tools (cont'd) Section C - Electrics 2A 2B 2C 2D 3A 3B 3C 3D 4A 4B 4C 4D 5A 5B 5C 5D

:7212/0002 :7212/0004 :7212/0003 :7212/0001 :7213/0002 :7213/0004 :7213/0003 :7213/0001 :7213/0006 :7213/0008 :7213/0007 :7213/0005 :7214/0002 :7214/0004 :7214/0003 :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 6B 6C 6D 7A 7B 7C 7D 8A 8B 8C 8D 9A 9B 9C 9D 10 11 12

:7216/0002 :7216/0004 :7216/0003 :7216/0001 :7218/0002 :7218/0004 :7218/0003 :7218/0001 :7219/0002 :7219/0004 :7219/0003 :7219/0001 :7219/0006 :7219/0008 :7219/0007 :7219/0005 :7210/0001 :7210/0002 :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

S188380

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4-6

Service Tools (cont'd) Section E - Hydraulics

Hydraulic Circuit Pressure Test Kit 892/00253 :892/00201 :892/00202 :892/00203 :892/00254 993/69800

S267300

892/00706

Pressure Test Kit Replacement Gauge 0-20 bar (0-300 lbf/in2) Replacement Gauge 0-40 bar (0-600 lbf/in2) Replacement Gauge 0-400 bar (0-6000 lbf/in2) Replacement Hose Seal Kit for 892/00254 (can also be used with probe 892/00706) Test Probe

S188121

S188131

Pressure Test Adapters Pressure Test 'T' Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265

1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1.1/4 in BSP x Test Point 5/8 in UNF x Test Point

S200141

Flow Test Equipment 892/00268 892/00269 892/00293 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277 892/00273 892/00294 1606/0015 892/00078 1604/0008 1606/0012 816/20013

9803/3270

Flow Monitoring Unit Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Connector Pipe Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP Sensor Head 0 - 380 l/min Connector Pipe Adapter 1.1/4 in M BSP x 1 in M BSP Connector 1 in F x 1 in F BSP Adapter 1 in M x 1 in M BSP Adapter 1 in M x 3/4 in M BSP Adapter 3/4 in F x 1 in M BSP

S188151

Issue 1

Section 1

General Information

Section 1

4-7

4-7

Service Tools (cont'd) Section E - Hydraulics Components for Valve Block A.R.V. Testing *For 4CX Variable Flow machines use 25/201103 892/00881

Valve Spool Seal Fitting Tool

1 2 3 4 5 6

892/00309 : 892/00340 : 892/00341 : 993/68300 : 892/00343 : 892/00345 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 6 4

2

S261220

1

3 5 S196700

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279

Hand Pump Micro-bore Hose 1/4 in BSP x 3 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lbf/in2) Gauge 0 - 400 bar (0 - 6000 lbf/in2)

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 S188140

S193850

Male Adapters - BSP x NPT (USA only)

Male Adapters - BSP x BSP

816/00439 816/00440 816/15007 816/15008

1606/0003 1604/0003 892/00071 1606/0004 1606/0007 1604/0004 1606/0017 1606/0008 1606/0009 1604/0006 1606/0012 1606/0014 1606/0015

3/8 in. x 1/4 in. 1/2 in. x 1/4 in. 3/8 in. x 3/8 in. 1/2 in. x 3/8 in.

3/8 in. x 1/4 in. 3/8 in. x 3/8 in. 3/8 in. x 3/8 in. taper 1/2 in. x 1/4 in. 1/2 in. x 3/8 in. 1/2 in. x 1/2 in. 5/8 in. x 1/2 in. 3/4 in. x 3/8 in. 3/4 in. x 1/2 in. 3/4 in. x 3/4 in. 3/4 in. x 1 in. 3/4 in. x 1.1/4 in. 1 in. x 1.1/4 in.

S193860

9803/3270

Issue 2*

Section 1

General Information

Section 1

4-8

4-8


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

S193890

892/00047 892/00048 892/00049 816/50043 892/00051 816/50005 816/60096 816/00017

3/8 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/4 in. BSP (B) 5/8 in. BSP (A) x 1/4 in. BSP (B) 3/4 in. BSP (A) x 1/4 in. BSP (B) 1 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/2 in. BSP (B) 3/4 in. BSP (A) x 3/4 in. BSP (B) 1 in. BSP (A) x 1 in. BSP (B)

992/09100 892/00011

Excavator Spool Clamp Spool Clamp

S193900

Female Connectors 892/00074 892/00075 892/00076 892/00077

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

S216210

9803/3270

3/8 in. BSP x 3/8 in. BSP 1/2 in. BSP x 1/2 in. BSP 5/8 in. BSP x 5/8 in. BSP 3/4 in. BSP x 3/4 in. BSP

S193930

Issue 1

Section 1

General Information

Section 1

4-9

4-9


7mm 11o

S216230

20mm

892/00180

892/00181

Seal Fitting Tool for fitting 'O' ring and king ring to Danfoss Orbitrol Unit

10mm

5mm R

Replacement Plastic Boss

m 3m

110mm 175mm 3o R

1.4

mm

892/01027

Piston Seal Assembly Tool 338500

892/00334

Ram Seal Fitting Tool

S216250

S338410

Ram Seal Protection Sleeves

*892/00948 *892/00949

Charging Kit (without gauge) Gauge

892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/00167

For 25 mm Rod Diameter For 30 mm Rod Diameter For 40 mm Rod Diameter For 50 mm Rod Diameter For 50 mm Rod Diameter (slew ram) For 60 mm Rod Diameter For 60 mm Rod Diameter (slew ram) For 65 mm Rod Diameter For 70 mm Rod Diameter For 75 mm Rod Diameter For 80 mm Rod Diameter For 90 mm Rod Diameter

S308271

9803/3270

Issue 3*

Section 1

General Information

Section 1

4 - 10

4 - 10

Service Tools (cont'd) Section F - Transmission 892/00295

892/00825

End Float Setting Tool

Reverse Clutch End Float Setting Tool (Powershift transmission only)

S190760

S188190

990/00083

End Float Setting Tool 892/00812

Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling on Syncro Shuttle

S188180

892/00179

S196720

A B C

Bearing Press (use with appropriate adapters)

892/00920 892/00301 892/00302

S188210 S188200

992/07608 992/07609 992/07610 992/07611 992/07612 992/07613

Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter

892/00922

Flow Test Adapter Flow Test Adapter Flow Test Adapter

A

B

C

12.2” Torque Converter Alignment Tool

S188160 S267260

9803/3270

Issue 1

Section 1

General Information

Section 1

4 - 11

4 - 11

Service Tools (cont'd) Section F - Transmission

892/00224 Impulse Extractor Set for Hub Bearing Seals

S197070

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).

892/00225 892/00891 Fitting Tool Assembly for Wheel Hub Seals

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)

S227760

S216290

892/00817 892/00818 892/00819 892/00333

9803/3270

17 mm A/F x 3/4in. square drive 22 mm A/F x 3/4in. square drive 15 mm A/F x 1/2in. square drive 19 mm A/F x 3/4in. square drive

Issue 1

Section 1

General Information

Section 1

4 - 12

4 - 12


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 pinion flange while pinion nut is slackened or torque set 892/00174 Measuring Cup - Pinion Head Bearing S190770

S197040

892/00822 Splined Bolt Socket for driveshafts

S197060

892/00916

S216310

Clutch pack spring compressor 892/00182

Bearing Pad Driver

S259320

9803/3270

Issue 1

Section 1 4 - 13

General Information

Section 1 4 - 13


Fixture for Syncro Shuttle & Powershift Gearbox removal & replacement Manufacture locally - items 1 to 4 on this and next page. Note: When removing/replacing a Syncro Shuttle Gearbox, use items 1, 2 and 3. When removing/replacing a Powershift Gearbox, use items 1 and 4.

Fixture - Item 1

9803/3270

Issue 1

Section 1

General Information

Section 1

4 - 14

4 - 14


Fixture - Item 2

Fixture - Item 4 Fixture - Item 3

9803/3270

Issue 1

Section 1

General Information

Section 1

4 - 15

4 - 15


* Solid Spacer Setting Kit

1

3

2 S316260

1 892/00918 2 993/70111 3 921/52600 Comprises of: 921/52601 921/52602 921/52603 921/52604 921/52605 921/52606 921/52607 921/52608 921/52609 921/52610 921/52611 921/52612 921/52613 921/52614 921/52615 921/52616 921/52617 921/52618 921/52619 921/52620 921/52621 921/52622 921/52623 921/52624 921/52625 921/52626

Setting Tool Kit Breakback Torque Wrench Spacer Kit Spacer 12.75 Spacer 12.80 Spacer 12.85 Spacer 12.90 Spacer 12.95 Spacer 13.00 Spacer 13.05 Spacer 13.10 Spacer 13.15 Spacer 13.20 Spacer 13.25 Spacer 13.30 Spacer 13.35 Spacer 13.40 Spacer 13.45 Spacer 13.50 Spacer 13.55 Spacer 13.60 Spacer 13.65 Spacer 13.70 Spacer 13.75 Spacer 13.80 Spacer 13.85 Spacer 13.90 Spacer 13.95 Spacer 14.00

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

S197010

* 993/78200

Mainshaft Airline Adaptor (Powershift Transmission Only)

These test points can be left in position after testing.

9803/3270

Issue 2*

Section 1

General Information

Section 1

4 - 16

4 - 16


1

993/70100

Powershift Endfloat Checking Kit (Includes items 2 to 13)

2

993/70101

Base Plate

3

993/70160

Yoke Assy

4

993/70130

Mainshaft Adapter

5

993/70104

Mainshaft Pillar

6

993/70106

1 7

4

11

3

12

Layshaft/Reverser Pillar

7

993/70120

Layshaft Setting Assy

8

993/70140

Reverser Setting Assy

6

5 10 8

6 13 2

9† 1391/3305

Capscrew (M8x20) Flanged

10 826/01417

Setscrew (M10x30) Flanged

11 993/70111

Setting Wrench (this is not part of the kit)

9

A191642

A191642

12† 993/70112

Input Shaft Pillar

13† 993/70150

Input Setting Assy

†If these items are not in your kit they can be ordered separately but the base plate 2 will have to be drilled to secure item 12, see A and B. Measurements are in mm. Apply JCB Threadlocker And Sealer and tighten item 9 to 25-30 Nm (18-22 lbf ft).

8.5

10

20

15 12

B B

36 17 81.75 96.35

A191643

9

9803/3270

Issue 2

Section 1

General Information

Section 1

4 - 17

4 - 17

Service Tools (cont'd) Section K - Engine

892/00836 Lifting Wire Assembly (for engine removal) S192390

S219080

892/00041

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

A314530

*892/00936

Timing pin for fuel injection pump (AK, AM, AR)

*892/0104

Adaptor for compression testing (AK, AM, AR)

For details of other engine service tools refer to Perkins Service Manual, Publication No. 9806/0100 or 9806/2140 for low emission engines.

9803/3270

Issue 3*

Section 1

General Information

Section 1

5-1

5-1

Sealing and Retaining Compounds JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

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

4102/1212

50ml

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

4102/0551

50ml

For all retaining parts which are unlikely to be dismantled.

4101/0651

50ml

JCB Threadlocker and Sealer

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 4101/0251

10ml 50ml

Threadseal

A medium strength thread sealing compound.

4102/1951

50ml

Threadlocker

A locking fluid for use on threads larger than 50mm dia.

4101/0451

50ml

Activator

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

4104/0251 4104/0253

Aersol (1ltr) Bottle (200ml)

Cleaner / Degreaser

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

4104/1557

400ml

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

993/55700

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1206 4104/1203

30 ml 250 g

† Black Primer 206J

For direct glazing

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass

4102/0933

Black Polyurethane Sealant

To finish exposed edges of laminated glass

4102/2309

310 ml

JCB Cleaner & Degreaser

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

4104/1538

Aerosol

Direct Glazing Kit

9803/3270

Issue 3

Section 2

Care & Safety

Section 2

i

i

Contents

9803/3270

Page No.

Safety Notices

1-1

General safety

2-1

Operating safety

3-1

Maintenance safety

4-1

Issue 1

Section 2

Care & Safety

1-1

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

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Care & Safety

Section 2

2-1

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

! 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.

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-1-3-4

INT-1-3-7

! WARNING

! 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.

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

INT-1-3-5

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

9803/3270

Issue 1

Section 2

Care & Safety

Section 2

3-1

3-1

Operating Safety ! WARNING

! 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.

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-2-1-2

! 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-2-1-9/3

! WARNING

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.

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

INT-2-1-4

! WARNING

! 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.

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-2-1-5

INT-2-2-6

! WARNING

! DANGER

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.

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-2-1-6/1

! 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

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

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

9803/3270

Issue 2

Section 2

Care & Safety

Section 2

4-1

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 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 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 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 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.

! 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

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.

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

INT-3-1-6

9803/3270

Issue 1

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Care & Safety

Section 2

4-2

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.

! 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

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.

! 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

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

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 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

! 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

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

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Care & Safety

Section 2

4-3

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.

! 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.

! WARNING

3

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.

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.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

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

GEN-1-2

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

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

i

i

Contents

9803/3270

Page No.

Lubricants Health & Safety

1-1

Lubricants & Capacities

1-2

Service Schedules

2-1

Loader Arm Safety Strut - Fitting and Removing

3-1

Engine Panels - Removing and Fitting a Side Panel - Removing and Fitting the Access Panel - Removing and Fitting the Engine Cover

4-1 4-1 4-1

Greasing - Loader Arms - Backhoe - Kingpost - 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 - Front and Rear Propshafts - 6-in-1 Clamshovel - Backhoe Quick-Hitch - Loader Quick-Hitch - Stabilisers (Centremount Machines) - Hydraulic Pump Driveshaft - Knuckle (if fitted) - Backhoe Quick Hitch (Hydraulic)

5-1 5-2 5-2 5-3 5-3 5-4 5-4 5-5 5-5 5-6 5-6 5-6 5-6 5-7 5-7 5-7

Tyres and Wheels - Tyre Inflation - Checking the Wheel Nut Torques

6-1 6-1

Brakes - Checking The Foot Brake Fluid Level

7-1

Engine Air Filter - Changing the Elements

8-1

Engine Oil and Filter - Checking the Oil Level - Changing the Oil and Filter

9-1 9-1

Engine Cooling System - Checking the Coolant - Changing the Coolant - Adjusting the Fan Belt - Cleaning the Cab Heater Filter

10 - 1 10 - 1 10 - 2 10 - 2

Fuel system - Types of fuel - Fuel standards - Low temperature fuels - Filling the tank - Draining the filter - Changing the filter element - Draining the sediment bowl - Bleed the system

11 - 1 11 - 1 11 - 1 11 - 1 11 - 2 11 - 2 11 - 3 11 - 3

Issue 3

Section 3

Routine Maintenance

Section 3

ii

ii

Contents

9803/3270

Page No.

Syncro shuttle transmission - Checking the oil level - Changing the oil and filter

12 - 1 12 - 1

Powershift transmission - Checking the oil level - Changing the oil and filter

13 - 1 13 - 1

Hydraulic system - Checking the fluid level - Hydraulic tank cap - Changing the filter element

14 - 1 14 - 1 14 - 2

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

15 - 1 15 - 1 15 - 2 15 - 2

Front and rear axle (two wheel steer machines) - Checking the oil level - Changing the oil

15 - 3 15 - 3

Issue 1

Section 3 1-1

Routine Maintenance

Section 3

Lubricants - Health and Safety

1-1

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

2

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

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

3

Note the following when removing oil from skin: a Wash your skin thoroughly with soap and water.

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

b Using a nail brush will help. c Use special hand cleansers to help clean dirty hands.

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.

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.

Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

First Aid - Oil

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

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

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

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

Handling

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

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.

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.

Here are precautions to protect your health when handling used oil: 1

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

9803/3270

Issue 2

Section 3

Routine Maintenance

Section 3


1-2

1-2

3CX, 4CX AND VARIANTS ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal

INTERNATIONAL SPECIFICATION

†Fuel Tank (with toolbox) 110 24.2 Diesel Oil ASTM D975-66T Nos. 1D, 2D †Fuel Tank (without toolbox) 150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D Fuel Tank (All later m/c’s) 130 28.6 Diesel Oil ASTM D975-66T Nos. 1D, 2D †Initial build machines only, all machines built after Feb. 1997 have a 130 litre (28.6 gal.) capacity tank. * Engine (Oil) ➀

JCB 15W/40 Multigrade

SAE15W/40

2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB

-10 °C to 50 °C (14 °F to 122 °F)

API CF4/SG

9.7 11.0 10

2.1 2.4 2.2

JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)

SAE10W/30 API CE/SF

4 Wheel Steer Machines - Build AB

10.0

2.2

JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)

SAE10W API CD/SF

2 Wheel Steer Machines - Build AR - Build AK

11.0 10

2.4 2.2

JCB Super Multigrade 15W/40 -10°C to +50°C (14°F to 122°F)

SAE15W/40 CF-4/SG

4 Wheel Steer Machines - Build AK

10.0

2.2

JCB Super Multigrade 10W/30 -15°C to +40°C (5°F to 104°F)

SAE10W/30 CF-4/SG

Engine (Coolant)

23.0

5.1

JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures)

ASTM D3306, BS6580

Syncro Shuttle (2WD) ➁

14.4

3.2

JCB Special Transmission Fluid

ESP-M2C 33G


15.4

3.4

Friction modified oils MUST NOT be used (eg. Dexron ATF type)

Powershift ➁

14.75

3.25


15.4

3.4

Friction modified oils MUST NOT be used (eg. Dexron ATF type).

13 18

2.86 3.96

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).

Hubs (x2)

2.0

0.44

Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS)

18 2.0 23

3.96 0.44 5.0

Brake System - Standard - Servo

1.2 1.4

0.26 0.31

JCB Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Hydraulic System ➂

130

28.6

JCB High Performance Hydraulic Oil

Front Axle (4WD) Housing (2WS) Housing (4WS) ➅

ESP-M2C 33G

JCB Special Gear Oil Plus API-GL-4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).

ISO VG46

(Above 38 °C, 100 °F) JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)

9803/3270

ISO VG32

Issue 3

Section 3

Routine Maintenance

Section 3


1-3

1-3

ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal


Grease Points

---

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

JCB HP Grease or JCB Special MPL-EP Grease ➃

including extreme pressure additives Extending Dipper

---

Waxoyl ➄

Electrical connections

---

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

Power Sideshift Chains

---

JCB Chain Lubricant

9803/3270

Issue 3

Section 3

Routine Maintenance

Section 3


1-4

1-4

NORTH AMERICAN MACHINES - 214, 214E, 215, 215E, 217 ITEM

CAPACITY US Gal Liters

FLUID/LUBRICANT


†Fuel Tank (with toolbox) †Fuel Tank (without toolbox) Fuel Tank (All later m/c’s)

29 39.6 34.3

110 150 130

Diesel Oil Diesel Oil Diesel Oil

ASTM D975-66T Nos. 1D, 2D ASTM D975-66T Nos. 1D, 2D ASTM D975-66T Nos. 1D, 2D

2.6 2.9 2.7

9.7 11.0 10

JCB 10W or JCB 15W/40 Below 32 °F (0°C)

† API CF4/SG, † MIL-L-2104F

JCB 30W or JCB 15W/40 Above 32 °F (0°C)

† Note: spec given for 15W/40

Engine (Oil) ➀ 2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB 4 Wheel Steer Machines - Build AB

2.7

10.0

2 Wheel Steer Machines - Build AR - Build AK

13.2 12.0

2.4 2.2

JCB 15W/40 Engine Oil -10°C to +50°C (14°F to 122°F)

SAE15W/40 CF-4/SG

4 Wheel Steer Machines - Build AK

12.0

2.2

JCB 10W Engine Oil -20°C to +10°C (-4°F to 50°F)

SAE10W CF-4/SG

Engine (Coolant)

6.07

23

Anti-freeze/Water

ASTM D3306-74


3.2

14.4


ESP-M2C 33G


3.4

15.4

Powershift ➁

3.9

14.75


ESP-M2C 33G

3.4 4.8

13 18

JCB GL-5 80W/90 JCB GL-5 85W/140

API-GL-5

Hubs (x2)

0.5

2.0

Rear Axle (4WS) Housing Hubs (x2)

4.8 0.5

18 2.0

JCB Special Gear Oil Plus

API-GL-4

Rear Axle (2WS)

6.1

23


API-GL-4


0.32 0.37

1.2 1.4

Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID

130

Front Axle (4WD) Housing (2WS) Housing (4WS)

➅


34.3

JCB Hydraulic Fluid

ISO VG46

Grease Points

---

JCB Moly EP # 2 Grease

Lithium based, No. 2

Extending Dipper

---

Waxoyl ➄


---


†Initial build machines only, all machines built after Feb. 1997 have a 34.3 gal. (130 liter) capacity tank.

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3


1-5

1-5

NORTH AMERICAN MACHINES - 214e & 214Se ITEM

CAPACITY US Gal Liters

FLUID/LUBRICANT


Fuel Tank

34.3

130

Diesel Oil

ASTM D975-66T Nos. 1D, 2D

2.6

9.7

JCB 15W/40 -10°C to + 50°C (14°F to 122°F) JCB 10W -20°C to + 10°C (-4°F to 50°F)

CF 4/SG, SAE 15W/40

Engine (Oil) ➀ 2 Wheel Steer Machines - Build AR

CF 4/SG, SAE 10W

Engine (Coolant)

6.07

23

Anti-freeze/Water

ASTM D3306-74


3.8

14.4


ESP-M2C 33G


4.0

15.4

Front Axle Housing (2WS) Hubs (x2)

3.4 0.5

13 2.0

JCB GL-5 80W/90

API-GL-5

Rear Axle

6.1

23


API-GL-4


0.32 0.37

1.2 1.4

Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID


34.3

130

JCB Hydraulic Fluid

ISO VG46

Grease Points

---

JCB Moly EP # 2 Grease

Lithium based, No. 2

Extending Dipper

---

Waxoyl ➄


9803/3270

---


Issue 2

Section 3 1-6 ➀

➁

➂ *➃

➄

Routine Maintenance Lubricants & Capacities

Section 3 1-6

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

➅

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 Universal Anti-freeze is shown below. If any other anti-freeze is used, refer to the manufacturers' 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.

9803/3270

Issue 2*

Section 3

Routine Maintenance

Section 3

Service Schedules

2-1

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 Maintenance 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.

2-1

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

2-3-1-1

Pre-start Cold Checks Service Points and Fluid Levels ENGINE Oil level Oil and Filter ➃ Air Cleaner Outer Element ➅ Air Cleaner Inner Element Fuel Filter Fuel Filter Coolant Quality/Level Fuel Sedimenter Fan Belt Tension/Condition Valve Clearances and Clean Breather Gauze (if fitted)➂ Engine Mounting Bolts for Tightness ➂ Radiator All Hoses - Condition TRANSMISSION, AXLES AND STEERING Transmission Oil Level Transmission Oil Transmission Filter Axle Oil Level (incl. Hubs when applicable) ➀ Axle Oil (incl. Hubs when applicable) Axle Oil - Limited Slip Differential Tyre Pressures/Condition Front Hub Bearings ➂ Transmission Strainer Drive Shafts Steer Axle Movement/Shimming ➂ Steer Axle Pivots and Linkages ➆ Front Axle Main Pivot HYDRAULICS Oil Level ➁ Oil ➂ Oil Filter * Rams - Chrome Condition Pilot Filter 9803/3270

Operation

- Check - Change - Change - Change - Change - Drain - Check - Drain and Clean - Check - Check and Adjust

10 Hr

50 Hr

●

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- Grease - Grease

- Check

500 Hr

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1000 2000 Hr Hr

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- Check - Change - Change - Check - Change - Change - Check - Check - Clean - Examine/Grease - Check

†100 Hr

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Issue 3*

Section 3

Routine Maintenance

2-2

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 Filter Adapters BRAKES Brake System Fluid Level Brake System Fluid ➂ 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 ➅ Extending Dipper Hydraclamp ➂ 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 ➄ 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 ➂ Stall Speed ➂ Maximum No-Load Speed ➂ Exhaust Smoke (excessive) Exhaust System Security ➂ Air Inlet System Security Throttle System and Control Cable ➂ TRANSMISSION, AXLES AND STEERING Steer Modes - Operation/Phasing 2WD/4WD Selection Wheel Nuts Torque Forward/Reverse and Gear Change - Operation 9803/3270

Section 3

Service Schedules

Operation

2-2

10 Hr

50 Hr

- Clean - Clean - Change - Security/Grease - Clean

- Check - Change - Check and Adjust

†100 Hr

500 Hr ●

1000 2000 Hr Hr ●

● ● ●

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- 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

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†100 Hr

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Operation

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Issue 4*

Section 3 2-3

Routine Maintenance Service Schedules

Functional Test and Final Inspection

Operation

Hydraulic Speed Control - Operation (if fitted) Steer Circuit Pressure ➂

- Check - Check

Transmission Main Line Pressure ➂ Transmission Dump Operation Neutral Start Operation Clutch Pack Pressures ➂


HYDRAULICS MRV Pressure ➂ Operation All Services Hose Burst Protection Valves (if fitted) Offloader Valve Pressure ➂

- Check and Adjust - Check - Check - Check and Adjust

Auxiliary Circuit & Pressures ➂

- Check and Adjust

BRAKES Foot Brake - Operation Parking Brake - Operation Servo Operation (if fitted) 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. BODYWORK AND CAB Teeth and Side Cutters Doors and Windows - Fitment/Leaks Seat/Seat Belts

Section 3




2-3

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† Note: First 100 Hours Service only, to be completed by your JCB Distributor. ➀ Note: Check for leaks every 50 hours, check level if leaking.

➁ Note: Check the hydraulic fluid level with the loader and backhoe in the travel position. ➂ Note: Jobs which should only be done by a specialist are indicated by a ➂. ➃ Note: If operating under arduous conditions, change the engine oil and filter every 250 hours. ➄ 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. ➅ Note: If operating in dusty working environments, change more frequently.

➆ Note: The axles are factory greased with a high performace grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours.

9803/3270

Issue 2

Section 3

Routine Maintenance

Section 3

Loader Arm Safety Strut

3-1

Installing

Removing

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

1

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

Fully Raise the Loader Arms To take the weight off the safety strut.

2

Stop the Engine Remove the starter key.

! WARNING

2-1-1-6

1

Empty the Shovel and Raise the Loader Arms fully.

2

Stop the Engine

3-1

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

Remove the starter key. 3

! 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

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.

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.

A

C

Note: When lowering the loader, operate the control lever carefully. 'Feather' the lever to lower the loader very slowly. S215110

C B

S161710

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

Engine Panels

4-1

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.

4-1

Removing and Fitting The Engine Cover 1

Remove the side panels.

! WARNING A hot exhaust will burn you. Make sure the exhaust stack is cool before removing it. 2-3-1-6

2-3-1-4/1

1

2

Lift-off the stack C.

3

Remove bolts D and lift off the cover E.

4

Reverse the above procedure to refit the engine cover.

Raise and lock the Loader Arms.

! WARNING Do not remove the engine side panels while the engine is running. 2-3-1-5

2

Stop the engine and remove the starter key.

3

To remove a side panel: Insert the key in the side panel lock, turn the handle A and holding the handle A and grab handle B lift the panel off.

4

Reverse the above procedure to refit the panel, remember to lock the panel once it has been fitted.

Removing and Fitting the Access Panel

C

! 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

To gain access to the engine oil dipstick, there is a small access panel F fitted in the right hand side panel.

B F

To remove the access panel: 1

Make sure the park brake is engaged and the transmission set to neutral. If the loader arms are raised, lower them under their own weight, or fit the safety strut.

2

Use the starter switch key to unlock the panel.

3

Remove the panel (to prevent the panel from being lost, it is attached to a retaining wire).

4


D

A D

E

S265240

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

5-1

5-1

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

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.

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

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.

! 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.

Loader Arms For each grease point shown, there is another on the other side of the machine. Total 22 grease points.

Chock all four wheels before getting under the machine. 2-3-2-1

12

34

56

78

90

!@ £$

%^

&*

()

¼

9803/3270

S260190

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

5-2

5-2

* Kingpost

Backhoe 16 Grease Points

9 Grease Points

Note: Figure shows a typical boom and dipper arrangement.

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

9 !

1 0 2

3

4

@

5 6

£

78

S254690

$ 8 7

% 9

5

6

4 1

^

2

3

S254680

9803/3270

Issue 2*

Section 3

Routine Maintenance

Section 3

Greasing

5-3

5-3

Note: Grease point 5 is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

Front Axle (2 Wheel Drive Machines) 9 Grease Points

3

4 5

1

2

6

8

7

9

Front Axle (4 Wheel Drive Machines)

S260200

Note: Grease point 5 is a remote grease point mounted on the side of the mainframe chassis (near the left front wheel).

5 Grease Points

12

9803/3270

5

43

1

3

2

4

S260210

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

5-4

5-4

Note: Grease point 5 is a remote grease point mounted on the side of the front nose (near the left front wheel).

Front Axle (All Wheel Steer Machines) 5 Grease Points

5 12

34

1

2

3

S260220

4

Rear Axle (All Wheel Steer Machines) 4 Grease Points

12

34

S260230

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

5-5

Extending Dipper

5-5

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.

3

2

1

5-3-1-9

Extend the dipper. Coat the runners with Waxoyl as shown.

S157500

Rear Driveshaft 3 Grease Points

1

3

2

S140080

9803/3270

S157511

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

5-6

5-6

6 - In - 1 Clamshovel

Backhoe Quick-Hitch

3 grease points each end Total 6 Grease Points

Total 5 Grease Points

12

12

34

5 34

56 S137251

S089961

Stabilisers (Centremount Machines)

Loader Quick-Hitch

3 grease points on each stabiliser Total 6 Grease Points

2 grease points each end Total 4 Grease Points

3

3 2

1

4

2 1

S259390

9803/3270

S257250

Issue 1

Section 3

Routine Maintenance

Section 3

Greasing

5-7

Hydraulic Pump Driveshaft

5-7

Backhoe Quick-Hitch (Hydraulic) ! CAUTION

1 Grease Point

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.

1

5-3-1-9

Coat the slide A with Waxoyl . 4 Grease Points

Knuckle (if fitted) Refer to Backhoe greasing for the boom and dipper grease points. Total 2 Grease Points.

4 3 1 2 A

2 1

S256440

9803/3270

S211750

Issue 1

Section 3

Routine Maintenance Greasing

5-8

Section 3 5-8

Power Sideshift Total 4 Grease Points * Note: Release the kingpost clamps before greasing and lower the excavator to the ground.

2 1

3 4 A326770

9803/3270

Issue 2*

Section 3

Routine Maintenance

Section 3

Tyres and Wheels

6-1

6-1

Tyre Inflation

Checking the Wheel Nut Torques

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.

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

! 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.

Every day, before starting work, check that the wheel nuts are tight. The correct torques are shown in the table below.

2-3-2-7

Front - Nm 680

lbf ft 500

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.

Rear -

lbf ft 500

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 Tyre Sizes and Pressures (SPECIFICATION Section) for recommended tyres and pressures for your machine.

Nm 680

! 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

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.

S089571

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

Brakes

7-1

7-1

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 distributor. 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 distributor.

A

B

! 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

4

If required, carefully pour the recommended fluid (DO NOT USE ORDINARY BRAKE FLUID) until it reaches the correct level.

S605014

Refit the reservoir cap. Wipe up any spillage.

9803/3270

Issue 3

Section 3

Routine Maintenance

Section 3

Engine Air Filter

8-1

8-1

Changing the Elements !CAUTION

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.

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, disconnect induction hose from stub pipe A. Cover the end of the hose to prevent rain and dirt from getting into the engine.

A

* Note: On later machines the pulsation ring L is not fitted. 7

Refit the induction hose to stub pipe A. Make sure that the wire is connected to the Air Filter Blocked switch.

H

C K

F

J D L

N

G

M N E

9803/3270

C

B M

J

S257910

Issue 2*

Section 3

Routine Maintenance Engine Oil and Filter

9-1

Checking the Oil Level 1

Section 3 9-1

Changing the Oil and Filter


2

Remove the dipstick access panel.

3

Check that the oil level is between the two marks on the dipstick A. Add oil if necessary, through filler B. Make sure that the dipstick and filler cap are fully inserted and tightened.

! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. 2-3-3-2

! WARNING

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 gasoline, diesel fuel or kerosine to clean your skin. INT-3-2-3

1

Do Steps 1 to 2 of 'Checking the Oil Level'

2

Drain the oil: a Place a container that can hold at least 3.0 gal (12 liters) beneath the engine (to catch the oil). 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 25 lbf (34 Nm).

3

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.

4

Fill the system: Fill the engine to the max mark on the dipstick with new oil through the filler. See the chart at the end of the MAINTENANCE section for recommended oil grades. Wipe off any spilt oil. Check for leaks. Make sure the filler cap is correctly refitted.

5

Obtain oil pressure: 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).

6

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

A B D F G

C

E S6060

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

Engine Cooling System

10 - 1

10 - 1

Changing the Coolant

Checking the Coolant ! WARNING

! 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.

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

2-3-3-3

1

Park the machine on level ground. Engage the parking brake. Stop the engine and let it cool down.

1

Park the machine on level ground. Engage the parking brake. Stop the engine and let it cool down.

2

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.

2

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.

A

2-3-3-4

B

S260120

D

3

Remove drain plug C and let the coolant drain out. Make sure the drain hole is not blocked.

4

Disconnect the radiator hose at D and allow the coolant to drain. Flush the system using clean water.

5

Clean and refit plug C. Make sure it is secure. Reconnect the radiator hose

6

Use the necessary mix of clean, soft water and antifreeze. See Coolant Mixtures (MAINTENANCE section). Fill to the COLD/MIN level on coolant reservoir B.

7

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

8

Refit the filler cap. Make sure it is tight.

9

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. S260270

C

S148060

9803/3270

Issue 1

Section 3

Routine Maintenance Engine Cooling System

10 - 2

Adjusting the Fan Belt

10 - 2

Cleaning the Cab Heater Filter

! WARNING

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

Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

1

Section 3


2

Loosen pivot fastening bolts A and B. Loosen adjustment link fastening bolts C and D.

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.

3

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

Note: The compressed air must be set at a pressure no greater than 7 bar (100 lb/in2).

4

Tighten bolts C and D, then bolts A and B.

4

Refit the cover E and secure with the retaining screws (2 off).

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

A

B X

F

C D E S209411

9803/3270

S254720

Issue 1

Section 3

Routine Maintenance

11 - 1

Section 3

Fuel System

11 - 1

Types of Fuel

Low Temperature Fuels

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

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.)

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: 0.5% of mass (maximum) Distillation: 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 Perkins 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.

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

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

9803/3270

Issue 3*

Section 3 11 - 2

Routine Maintenance

Section 3

Fuel System

11 - 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. 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


2

Drain off any water in the element A by turning tap B

A B

Changing the Filter Element 1


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.

S260120

A

B

9803/3270

S233870

Issue 2

Section 3

Routine Maintenance Fuel System

11 - 3

Draining the Sediment Bowl 1

Section 3 11 - 3

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

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.

1


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.

C A B X

S260120

9803/3270

S148060

Issue 1

Section 3

Routine Maintenance Syncro Shuttle Transmission

12 - 1

Checking the Oil Level

12 - 1



* 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

2-1-1-6

1

Section 3

With the engine stopped, fill the transmission to maximum mark on dipstick/filler A. Use only the recommended oil.

2

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.

3

Stop the engine, wait approximately 20 seconds. Recheck the oil level and if required, fill to dipstick level.

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

C

A

2

Place a container that can hold at least 20.8 litres (4.6 gal) beneath the machine. (To catch the oil). 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.

B

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

F E

9803/3270

D

A332040

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.

Issue 2*

Section 3

Routine Maintenance Powershift Transmission

13 - 1

Checking the Oil Level

13 - 1



* 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

2-1-1-6

1

Section 3

With the engine stopped, fill the transmission to maximum mark on dipstick/filler A. Use only the recommended oil.

2

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.

3

Stop the engine, wait approximately 20 seconds. Recheck the oil level and if required, fill to dipstick level.

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.


E

D

2

Place a container that can hold at least 14.75 litres (3.3 gal) beneath the machine. (To catch the oil). 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:

C

F

A

5.1 Smear seal C with transmission oil. 5.2 Screw the filter on until it just contacts the filter head.

B

5.3 Turn the filter at least another 3/4 of a turn. 6

A332050

9803/3270

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.

Issue 2*

Section 3

Routine Maintenance

Section 3

Hydraulic System

14 - 1

Checking the Fluid Level

14 - 1

Hydraulic Tank Cap

! 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.

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.

INT-3-1-10/1

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.

1

Fit the Cap

2

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. Look at the fluid level in the sight glass A. The level should be at the red mark (or above).

* Insert the key and turn anticlockwise D, screw the cap on until resistance is felt then turn a further quater 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

! 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.

Insert the key and turn anticlockwise D, unscrew the cap.

2-3-4-3

3

If necessary, add recommended oil through the filler cap B.

B

B

D A

E C S260280

9803/3270

A329760

Issue 3*

Section 3

Routine Maintenance

Section 3

Hydraulic System

14 - 2

14 - 2

Changing the Filter Element ! WARNING

3

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

2

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. Remove the element assembly. a Remove screws A. Remove the cover plate B and gasket C, discard the gasket. b Remove spring D. c Hold handle E and pull the element assembly from the hydraulic tank.

Remove the element from its canister. a Hold canister F. b Hold handle E and rotate the element G 90° anticloclwise. 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 a new gasket C. 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.

E J

G A B D

C

H F

S260300

9803/3270

Issue 2*

Section 3

Routine Maintenance

Section 3

Hydraulic System

14 - 3

14 - 3

Changing the Suction Strainer From machine serial number 483131 the suction strainer is in the hydraulic return line.

6

Fit a new filter assembly B, torque tighten to 15-20 Nm (11-15 lbf ft).

! WARNING

7

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.

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 Filler Cap this section.

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 this section.

Changing the Pilot Filter (Servo Machines Only) ! 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

4

Undo clips A and disconnect the hydraulic return pipe.

5

Using a 65mm A/F spanner unscrew suction strainer B and discard.

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.

2

With the engine stopped, turn the starter switch to ON. Operate the joystick controls to exhaust pilot pressure. Switch the starter OFF and disconnect the battery.

3

Place a container beneath the manifold to catch the oil, undo filter cap C slowly to make sure there is no residual pressure still in the system, remove and discard filter D.

4

Fit new filter D, refit filter cap C and torque tighten to 85 Nm (62 lbf ft).

5

Check hydraulic fluid level and fill as required.

B

D A

C

A A334050

9803/3270

A334230

Issue 2

Section 3

Routine Maintenance

Section 3

15 - 1

Front and Rear Axle (All Wheel Steer Machine)

15 - 1

Checking the Differential Oil Level

Changing the Differential Oil

! WARNING

! WARNING



2-3-2-2

2-3-2-2

! CAUTION

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).

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


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.

REAR

FRONT

S260420

A A

B

B S260430

9803/3270

Issue 1

Section 3

Routine Maintenance

Section 3

15 - 2

Front and Rear Axle (All Wheel Steer Machine)

15 - 2

Checking the Hub Oil Levels Check each hub separately

*1

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

OIL LEVEL

C

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 recommended oil. Clean the plug before refitting it.

Changing the Hub Oil Change the oil in each hub separately 356040

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.

C

S209320

9803/3270

Issue 2*

Section 3

Routine Maintenance

Section 3

15 - 3

Front and Rear Axle (Two Wheel Steer Machine)

15 - 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.

Changing the Oil 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. Place a container of suitable size beneath the drain plug B to catch the oil.

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


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.

4

3

Clean and refit the plug and its washer.

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

! CAUTION 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 A B S209320

9803/3270

S145210

Issue 1

Section A

Attachments

Section A

i

i

Contents Extradig Dipper Wear Pads - Upper/Lower Inspecting the Top Wear Pads Adjusting the Bottom Wear Pads

9803/3270

Page No. 4-1 4-2

Issue 1

Section A

Attachments

Section A

Extradig Dipper Wear Pads - Upper/Lower

4-1

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.

4-1

Inspecting the Top Wear Pads Park the machine on level ground. Engage the parking brake and put the transmission in neutral. 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.

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.

* Renew the pads when, or before they are worn down to the

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, page A/4 - 2.

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.

New wear pads A and B must be replaced as a set and fitted by a qualified service engineer.

Note:The illustration shows both the earlier type wear pad with a recess and the later type with a chamfer.


Torque Settings Item F

Nm 56

kgf m 5.7

lbf ft 41

F

A E

B

A

B

J

A

A

E B

B

D C

S312991

9803/3270

Issue 2*

Section A 4-2

Attachments Extradig Dipper Wear Pads - Upper/Lower

Section A 4-2

Adjusting the Bottom Wear Pads Park the machine on level ground. Engage the parking brake and put the transmission in neutral. Support the boom and dipper as shown at C. Stop the engine. Clean the sliding faces of the inner dipper with a suitable solvent. Start the engine. Retract the Extradig dipper D. Make sure that the bucket is clear of the ground and the dipper is supported. Stop the engine. 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). Note:The illustration shows both the earlier type wear pad with a recess and the later type with a chamfer.

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.

S148121

9803/3270

Issue 2

Body & Framework

Section B

Section B

i

i

Contents Engine Panels - Removing and Fitting a Side Panel - Removing and Fitting the Access Panel - Removing and Fitting the Engine Cover

1-1 1-1 1-1

Rivet Nuts - Fitting Procedure - Specifications

2-1 2-1

Slide Hammer Kit - Procedures

3-1

Cab Rops/Fops Structure - Checking

4- 1

Glazing - General - Direct Glazing

5-1 5-1

Loader Front End Loader Arms - Removal and Replacement

6-1

Stabiliser Legs (Centremount Machines) - Removal and Replacement

7-1

Stabiliser Legs (Sideshift Machines) - Wear Pads - Wear Pad Adjustment - Removal and Replacement

7-3 7-3 7-3

Kingpost - Removal and Replacement

8-1

Boom & Dipper - Dipper Removal and Replacement - Boom Removal and Replacement

9-1 10 - 1

Sideshift - Setting Clearance - Carriage/Hydraclamp - Power Sideshift Wear Pad - Power Sideshift Chains - Power Sideshift Ram

11 - 1 11 - 2 11 - 3 11 - 4

* Rear Electric Window - Open/Close The Window - Manual Operation - Reset Procedure - Fault Finding

9803/3270

Page No.

12 - 1 12 - 1 12 - 1 12 - 2

Issue 5*

Body & Framework

Section B

Section B

ii

ii

Contents Air Conditioning - Technical Data - Safety Procedures - Operation - Control - Fault Finding - Checking Refrigerant Charge Level - Refrigerant Charging & Discharging - Leak Testing - Tightening Leaking Hoses - Blower Motor Removal and Replacement - Pressure Switches - Testing - Removal and Replacement - Condensor Coil Cleaning - Adjusting the Compressor Drive Belt

Page No. 14 - 1 14 - 1 14 - 2 14 - 3 14 - 4 14 - 6 14 - 6 14 - 6 14 - 6 14 - 21 14 - 22 14 - 22 14 - 23 14 - 24

* Hydraulic Tank - Removal and Replacement

9803/3270

15 - 1

Issue 2*

Section B

Body & Framework Engine Panels

1-1

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

1

Section B

Raise and lock the Loader Arms.

! WARNING

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

1-1

Removing and Fitting The Engine Cover 1

Remove the side panels.

! WARNING

A hot exhaust will burn you. Make sure the exhaust stack is cool before removing it. 2-3-1-6

2

Lift-off the stack C.

3

Remove bolts D and lift off the cover E.

4

Reverse the above procedure to refit the engine cover.

2-3-1-5

2


3

To remove a side panel: Insert the key in the side panel lock, turn the handle A and holding the handle A and grab handle B lift the panel off.

4

C


Removing and Fitting the Access Panel

B F

! 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

D

To gain access to the engine oil dipstick, there is a small access panel F fitted in the right hand side panel.

A D

To remove the access panel: 1


2

Use the starter switch key to unlock the panel.

3

Remove the panel (to prevent the panel from being lost, it is attached to a retaining wire).

4


9803/3270

E

S265240

Issue 1

Section B

Body & Framework

Section B

Rivet Nuts

2-1

2-1

Fitting 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 cab floor plate 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.

A

B

C

D

E

Specifications (all dimensions in mm) Rivet Nut Thread Diameter

Rivet Nut Outside Diameter

Material Thickness

Rivet Length (Total)

Drill Hole Dia.

M5

7

0.25 - 3.00 3.00 - 5.50

14.00 17.00

7.10

M6

9

0.50 - 3.00 3.00 - 5.50

16.00 19.00

9.10

M8

11

0.50 - 3.00 3.00 - 5.50

18.00 21.00

11.10

1.00 - 3.50 3.50 - 6.00

23.00 26.00

13.10

S150970

M10

9803/3270

13

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.

Issue 1

Section B

Body & Framework

Section B

Slide Hammer Kit

3-1

3-1

Procedures 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.

5

Fit the 'slide hammer', item F, onto the slide bar as shown.

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.

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.

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.

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.

4

Fit the 'slide bar' E into the end stop. Again make sure that the threads are fully engaged.

8

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

C

A

B

E

F

C

D S196900

9803/3270

Issue 1

Section B

Body & Framework

Section B

4-1

ROPS/FOPS Structure

4-1

Checking the ROPS/FOPS Structure ! 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. 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

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) Bolts C 205 Nm (150 lbf ft)

C A B

S260180

9803/3270

Issue 2*

Section B

Body & Framework

Section B

Glazing

5-1

5-1

Glazing - General

Direct Glazing

The sectional diagram below provides a comparison between rubber seal glazing (item A) and direct glazing (item B).

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:

The Backhoe Loader machine from serial number 460001 is all direct glazing.

A

B

A191050

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, Section 1).

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, Section 1). 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). Removing the Broken Glass and Old Sealant 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

9803/3270

Issue 2

Section B

Body & Framework

Section B

Glazing

5-2

5-2

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

b

3

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.

A

Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant.

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.

S186380

B

Note: This tool must not be used on toughened glass (see WARNING on previous page). (i)

D C

D

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

(i)

E

E D

Braided Cutting Wire and Handles B. This method uses a 3-core wire, a wire starter tube and two handles (see Service Tools, Section 1).

S189870

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.

C

(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. S189880

(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.

9803/3270

Issue 1

Section B

Body & Framework Glazing

5-3

Section B 5-3

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, Section 1. (i)

Insert the knife blade into the sealant.

(ii)

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)

Insert the knife blade into the sealant.

(ii)

Pull the knife along and cut out the old sealant.

F

G

S189890

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, Section 1, for details of this and any other tools. 4

H

a Laminated glass - lift out the broken pane using glass lifters (see Service Tools, Section 1). b Toughened glass - remove the cut off sealant and all remaining particles of shattered glass. S186380

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:

J

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.

S189900

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.

9803/3270

Issue 1

Section B

Body & Framework

Section B

Glazing

5-4

Direct Glazing (cont'd) Preparing the New Glass

5-4

K

! CAUTION

M

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.

L

b Install the new glass on the spacer blocks - ALWAYS USE GLASS LIFTERS M (see Service Tools, Section 1). 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.

S189910

N

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, Section 1).

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.

S186280

P

S186291

R

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. S189920

9803/3270

Issue 1

Section B

Body & Framework

5-5

Section B

Glazing

5-5

Direct Glazing (cont'd) Preparing the New Glass (cont'd) 5

S

Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds, Section 1 and Note 2 below) into a suitable applicator gun:

10-15 mm

a Remove the aluminium disc cover from the base of the cartridge and discard the 'dessicant capsule'.

T

8-10 mm 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.

A186410 A186410

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.

T

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.

S189930

W

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'.

Typical m/c installation

S186440

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:

X

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. S189910

9803/3270

Issue 1

Section B

Body & Framework Glazing

5-6

Section B 5-6

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, Section 1).

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

6

Clean the glass using a purpose made glass cleaner.

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.

9803/3270

Issue 1

Section B

Body & Framework

Section B

Loader Front End

6-1

6-1

A X B

DE

T R U H

FG

S Y

K L

M

P Q

H

Z

K L

S265931

9803/3270

Issue 2

Section B

Body & Framework

Section B

Loader Front End

6-2

6-2

Loader Arms ! WARNING

Removal and Replacement Removal 1

2

Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral. 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 cover, see page B/1-1.

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.

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 993/68100).

16

Repeat steps 13 to 15 for the opposite level link pivot pin.

17

Remove klipring M and shim P.

* Note:

Machines from serial number 498504, (except 214e and 214Se) klipring M has been replaced with retaining ring R, nut S and bolt T. 18

Remove pivot pin Q/U (use slide hammer kit 993/68100)

19

Repeat steps 17 and 18 for the opposite loader arm pivot pin. When all four pivot pins have been removed, carefully reverse the machine clear 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.

20

7

Remove the lift ram pivot pins A.

Replacement

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.

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.

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.

All klipring installations to have a maximum end float of 2 mm (0.078 in).

10

Disconnect the electrical connections (not shown) to the loader shovel reset switch (if fitted).

If fitting new liner bearings, assemble with a close fitting shouldered mandrel to ensure minimum ovality.

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.

9803/3270

Issue 2*

Body & Framework

Section B

Section B

Stabiliser Legs

7-1

7-1

G F

D C

A

B

S261790

9803/3270

E

S216810

Issue 1

Body & Framework

Section B

Section B

Stabiliser Legs

7-2

7-2

Stabiliser Leg (Centremount Machines) Removal and Replacement

5

Remove the stabiliser leg:

Removal 1

! CAUTION

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.

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

5.1 Wrap a suitable sling around the stabiliser leg, make sure that the weight of the leg is supported by the sling. 5.2 Remove the stabiliser leg pivot pin retaining nut and bolt, drive out the stabiliser leg pivot pin, as shown at G. 5.3 Remove the stabiliser leg.

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:

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.

4.1 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. 4.2 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

4.3 Wrap a suitable sling around the stabiliser ram, make sure that the weight of the ram is supported by the sling. 4.4 Remove the ram pivot pin retaining nut and bolt, drive out the ram pivot pin as shown at F. 4.5 Remove the stabiliser ram.

9803/3270

Issue 1

Section B 7-3

Body & Framework

Section B

Stabiliser Legs

7-3

A

C B

S271850

9803/3270

Issue 1

Section B

Body & Framework

7-4

Section B

Stabiliser Legs

7-4

Stabiliser Leg (Sideshift Machines) Wear Pads

Stabiliser Leg Removal and Replacement

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’.

Removal 1 Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral.

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

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, see page E/23-3.

5

Remove the inner leg: 5.1 Locate a suitable jack underneath the inner leg.

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 (see procedures on this page). 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. Before fitting new pads, check the condition of the stabiliser legs, make sure there are no grooves, nicks etc (caused by bucket teeth coming into contact with the legs). Dress off all burrs, nicks and grooves, this will help promote a longer wear pad life. Wear Pad Adjustment 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.

5.2 Use the jack to lift the inner leg until the top wear pads A protrude from the top of the outer leg section. 5.3 Remove the wear pads and attach suitable lifting gear through the wear pad locating holes. 5.4 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 as described in ‘Wear Pad Adjustment’.

* Apply a grease such as JCB slew grease (part number 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.

9803/3270

4003/1601) to the threads of pad B.

Issue 2*

Section B

Body & Framework

Section B

Kingpost

8-1

8-1

72 71 m 14 oom Pivot Bearing - 15ft 6in / 17ft Backhoe)

Item 14 (Boom Pivot Bearing - 14ft Backhoe)

A261800

70

83

65

80

Kingpost - Removal and Replacement

57 Item 15 (Kingpost Pivot Bearing)

A252870

17

7

A252880

11

8 15

9 10 5

17

6

4 12

6

13

14

17 15

2 17

16

13

14

3A

16 1 3A

S254893

3 9803/3270

Issue 4

Section B

Body & Framework Kingpost

8-2

Section B 8-2

Kingpost - Removal and Replacement Removal

Replacement

1

Slew the kingpost to the centre and remove the boom and dipper.

Replacement is generally a reversal of the removal procedures, however note the following:

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.

To assist with the identification of 15ft 6in and 17ft centremount kingposts the number ➏ is stamped on the

! WARNING

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).

* Note: Later machines are fitted with 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.

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.

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.

9803/3270

Issue 3*

Section B 9-1

Body & Framework

Section B

Boom and Dipper

9-1

F G

E

J K H

B

A C

D

L S266170

9803/3270

Issue 1

Section B

Body & Framework

Section B

Boom and Dipper

9-2

9-2

Dipper Removal and Replacement Removal

*

Replacement

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.

! 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.

INT-3-1-11/1

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.

9803/3270

Issue 2*

Section B

Body & Framework

Section B

Boom and Dipper

10 - 1

E

10 - 1

G

F B

K

H

J L A

C

D

9803/3270

Issue 1

Section B

Body & Framework

Section B

Boom and Dipper

10 - 2

10 - 2

Boom Removal and Replacement Removal

Replacement

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).

! 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

4

Operate the backhoe control levers back and forth several times to release pressure trapped in the hydraulic hoses.


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, spacer J, shim K and pivot pin L.

11

Hoist the boom clear of the kingpost assembly.

9803/3270

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 shim, item K is installed as shown. Note: A range of spacers J, (5, 6, 8 mm: 0.19, 0.23, 0.31 in)

* fitted either side of the kingpost have been introduced to eliminate the use of shim K. Replace all pivot pin seals as required.

Issue 2*

Section B

Body & Framework Sideshift

11 - 1

Section B 11 - 1

Setting Clearance - Carriage/Hydraclamp 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.

* Note: From machine serial number 486574 new hydraclamp cylinders and securing pins have been introduced which are more tolerant to larger clearances. To enable identification, the old pistons are yellow and the new pistons are black. * Components of the hydraclamps are not interchangeable but complete assemblies are provided they are set to the larger clearance. 2 *3

4

Select the carriage clamps to lock. 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

2 - 4 mm (0.08 - 0.16 in)

New type manual

3 - 5 mm (0.11 - 0.19 in)

Power

3 - 5 mm (0.11 - 0.19 in)

Release the clamps and tighten/loosen nut 1 as required, recheck measurement. When correct bend tab to lock nut.

D A

1 D B

D C

338630

9803/3270

Issue 2*

Section B

Body & Framework

Section B

Sideshift

11 - 2

11 - 2

Power Sideshift Wear Pad * Inspection (1000 hours)

Assembly 9 Fit wear pad H, plate J and bolt D.

When the wear pads are worn to 6 mm (0.23 in) or below they should be replaced. The later type pads, (with straight grease nipples) 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.

10

Fit new lock tab B and fit nut C.

11

Set the hydraclamp clearance as described on the previous page.

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 rotating the wear pad the grease nipples will have to be swopped over. Dismantle 1

2

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

H

J

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.

D E

G B C

F

K

A A326840

9803/3270

Issue 2*

Section B

Body & Framework

Section B

Sideshift

11 - 3

11 - 3

Power Sideshift Chains The chain tension should be checked at the initial 100 hours service and every 500 hours.

Removal 1


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.

Check and Adjust 1


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.

Assembly 4

5

If adjustment is required, slacken locknuts C and adjust on nuts B as required, tighten locknuts C on completion.

1

Thread the chains around the pulley and secure to the carriage with pin E, fit new split pins D.

Repeat steps 3 and 4 for the opposite pair of chains.

2

Connect chain adjusters, tension chains as required, see Check and Adjust.

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.

D E D

A

B

C

B

C

A326830

9803/3270

Issue 2*

Section B

Body & Framework

Section B

Sideshift

11 - 4

11 - 4

Power Sideshift Ram Removal

Replacement

1


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

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.

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, see Sideshift Chains, Check and Adjust.

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.

C E D

B

A

A326850

9803/3270

Issue 2*

Section B

Body & Framework

Section B

Rear Electric Window Option

12 - 1

The powered rear window will automatically open (or close) when rocker switch A is pressed. The switch has three positions: I Centre position - the powered window is inactive. II Top position - the powered window will fully open. III Bottom position - the powered window will fully close. When the window is automatically opening (or closing), a warning buzzer will sound. Make sure hands, feet, loose clothing etc. are kept clear of the moving window. If the window is closing and a block condition is detected, the window will reverse direction to the fully open position. It will remain open until ‘close’ is once again initiated.

12 - 1

Reset Procedure If the battery has been disconnected, or power interrupted (e.g. blown fuse), on reconnection it will be necessary to allow the window control unit to re-calibrate itself: 1

Following battery reconnection press the rocker switch (to open the window).

2

Once the window has fully opened, press the rocker switch (to close the window).

Note: If for any reason the open/close cycle is interrupted, repeat steps 1 and 2.

! WARNING Make sure hands, feet, loose clothing etc. are kept clear of the moving window. Failure to keep clear may result in personal discomfort or injury. 2-2-1-13

Open/Close the Window To open or close the rear window, touch the rocker switch once, it is not necessary to hold the switch. The window will automatically stop when it reaches the fully open or closed position. The window will not be operational unless the forward/reverse lever is in neutral position. If the window will not fully open/close interrupt the power (remove fuse and then re-insert) and complete steps 1 and 2 of Reset Procedure. Before closing the window, make sure that the window wiper lead will not be trapped. When leaving the machine, for security, make sure that the bottom locking levers are in the lock position. Manual Operation

! CAUTION

The rear window is heavy. Take care when raising and lowering it. If necessary, slide the seat towards the loader to give you more room when moving the window.

B

2-2-1-5

S276630

In the event of an electrical failure, the window can be manually opened or closed. It should be noted that there will be no gas struts to assist with opening or closing, the window will be heavy. Release screws B (do not fully remove) and open or close the window as required. DO NOT operate the machine with the window in the open position and the screws B released.

A

S252511

9803/3270

Issue 1

Section B 12 - 2

Body & Framework

Section B

Rear Electric Window Option

12 - 2

Fault Finding Fault Window fails to operate.

Cause Check the transmission is in neutral. Check fuse A6.

During opening or closing the window gets part way then returns to its start position.

1

Electronic Control Unit (ECU) not calibrated. Tight spot in window frame. Drive cables out of phase or too tight.

ECU not calibrated

1

Refer to Reset Procedure, see page B/12-1. 2

Tight spot in window frame. The ECU constantly measures the motor speed, if the motor slows down for any reason the ECU will stop the motor and reverse direction preventing a block condition. If there is a tight spot in the roller track the ECU may reverse the motor.

3 2

A tight spot may be caused by misalignment, lack of lubrication or physical damage. Release screws B and manually move the window through the operating range. Rectify any tight spots as required. Calibrate the ECU. 3

Drive cables out of phase or too tight. Undo bolts 1, remove window motor 2 and drive gear 3. Release screws B and slide blocks 4 fully forward or rearward. Refit drive gear 3 and window motor 2. Tighten screws B and calibrate the ECU.

9803/3270

B

4 S347880

Issue 1

Section B 14 - 1

Technical Data Refrigerant R134a System Capacity 1200g (2 lb 10oz) Switch Pressures Low Pressure Switch (white) Cut in = 3.2 bar max. (47 lbf/ in2 max.) Cut out = 1.6-1.8 bar (23-26 lbf/ in2) High Pressure Switch (blue) Cut in = 15.2-19.3 bar (220-280 lbf/ in2) Cut out = 26.2-29 bar (380-420 lbf/ in2)

Body & Framework

Section B

Air Conditioning

14 - 1

Safety Procedures The air conditioning system uses refrigerant under pressure in a closed circuit. 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 suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/2

1

It is critical that the correct refrigerant 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

9803/3270

3

Do Not perform welding operations close to refrigerant hoses (maintain a distance of at least 0.5m (1.5 ft) 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.

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

14 - 2

14 - 2

B

A

D

E

L

C

K

F

G

Operation

S257691

9803/3270

Issue 1

9803/3270

High pressure gas leaves the compressor and enters the condenser B. Ambient air is drawn across the condenser fins by the engine driven cooling fan and the gas is cooled. In the condenser, the refrigerant changes state to a high pressure liquid.

The action of the compressor changes the state of the refrigerant from a low pressure gas to a high pressure gas.

The compressor A draws in low pressure refrigerant gas from the accumulator C. The accumulator contains a desiccant bag which retains any liquid that may be in the system. This insures that liquid refrigerant will not enter and damage the compressor.

The low pressure gas is now drawn by suction back to the compressor via the accumulator, where the cycle begins again.

The refrigerant passes from the condenser to the evaporator E via metering orifice tube D. The orifice tube monitors the amount of refrigerant entering the evaporator and therefore reduces the pressure of the refrigerant. Air in the cab is forced through the evaporator coil by a blower fan. Heat is transferred from the ambient and recirculated air to the refrigerant, causing the low pressure liquid to vapourise and become a low pressure gas. The resulting cool air is circulated to the interior of the cab through ducts and vents.

The (blue) high pressure switch L is located in the pipe that connects the condenser B to the evaporator E. If the pressure rises above the high pressure switch setting, the switch opens, interrupting the electrical supply to the compressor clutch. Continued high pressure is likely to damage hoses and seals. The most likely reason for excessively high pressure is debris causing a blockage in the condenser B or the orifice tube D.

The (white) low pressure switch K is located in the pipe that connects the evaporator E to the accumulator C. If the pressure falls below the low pressure switch setting, the switch opens, interrupting the electrical supply to the compressor clutch. Low pressure leads to a lack of refrigerant borne lubricant for the compressor which can suffer severe damage as a result. Possible causes of the low pressure are low refrigerant charge or low ambient temperatures.

Current is fed to the field coil through three switches in series; 1) the manual ON/OFF switch F; 2) a low pressure switch K; 3) a high pressure switch L.

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 rotor. Since the clutch assembly is turned constantly by the crankshaft pulley drive belt, the compressor armature turns, starting the refrigeration cycle.

Control

14 - 3

To operate the air conditioning, the operator presses the air conditioning switch F to the ON position. Control G is rotated anti-clockwise to decrease the temperature from ambient to cold. Air vents can be adjusted to vary and direct the airflow.

The major components of the system are the compressor A, condenser B, accumulator C, orifice tube D and evaporator coil E.

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.

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 coil in the air conditioning unit.

Operation

Section B Body & Framework Section B

Air Conditioning 14 - 3

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

14 - 4

14 - 4

Fault Finding 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. 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 accumulator pressure-

Plugged orifice tube Repair or replace accumulator Evacuate & recharge

Condenser coil air flow restricted -

Remove debris from around coil using compressed air or low pressure water.

System overcharged-

Evacuate & recharge

b)

Blower operates on fan speed 3 only

Blower resistor failed -

Renew resistor.

c)

Compressor clutch continually cuts out

Condenser coil blockage Overcharging of refrigerant system-

Remove debris from around coil/renew condenser. Evacuate and recharge system.

Wiring Diagram Use the illustration below to complete continuity checks on the air conditioning system harness wires. Refer also to the main machine circuit diagram in Section C. Key 40 41 42 92 93 94 95

Heater Motor Heater Resistor Air Conditioning Compressor Heater Switch Air Conditioning Switch Air Conditioning Pressure Switch Air Conditioning Pressure Switch

FUSE A6

FUSE C7

40

122

41

92 94

93

9803/3270

95

42 A257780

Issue 1

Section B

Body & Framework

14 - 5

Section B

Air Conditioning

14 - 5

No Air Conditioning CHECK

ACTION

1

Are the controls set correctly, i.e. air conditioning selected, thermostat switch set to coldest position and blower switched on?

YES: NO:

Check 2 Reset controls and retest.

2

Is the air conditioning (evaporator) blower working?

YES: NO:

Check 3. Check 4.

3

Is the compressor running (visual check of pulley/clutch)?

YES: NO:

Check11. Check 7.

4

Is the air conditioning fuse blown?

YES: NO:

Renew fuse and retest. Check 5.

5

Is there a 12V supply to the pressure switch harness? (See Pressure Switch Testing)

YES: NO:

Check 6. Check 9.

6

Does the compressor clutch engage with both pressure switches bypassed? (See Pressure Switch Testing)

YES: NO:

Check 7. Renew the compressor clutch and retest.

7

Does the compressor clutch engage with HP switch bypassed? (See Pressure Switch Testing)

YES: NO:

Renew high pressure switch and retest. Check 8.

8

Does the compressor clutch engage with LP switch bypassed? (See Pressure Switch Testing)

YES: NO:

Renew low pressure switch and retest. Charge check required by refrigeration engineer.

9

Are blower switch and wiring OK?

YES: NO:

Renew blower motor. Renew switch or wiring.

10 Is condenser air flow blocked?

YES: NO:

Clean condenser and radiator. Check 11.

11 Is evaporator air flow blocked?

YES: NO:

Clean filter and, if necessary the evaporator. Call in refrigeration engineer.

9803/3270

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

14 - 6

Checking Refrigerant Charge Level If the air conditioning system is not performing adequately complete the fault finding procedures.

Refrigerant Charging & Discharging

14 - 6

Leak Testing ! WARNING Leak testing in Air Conditioning systems should be carried out only in a well ventilated area. BF 1-2

Procedures for charging and discharging the system are not given in this manual as they require special equipment and training.

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.

Training can be arranged through the JCB International Training Centre.

Hose or pipe connections are likely leakage points of any refrigerant circuit.

The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. The service valves are Schrader type and can be located at the compressor A, on the suction and discharge ports. The (white) low pressure switch K is located in the pipe that connects the evaporator to the accumulator. The (blue) high pressure switch L is located in the pipe that connects the condenser to the evaporator.

* It

is essential that an electronic detector is used to locate leaks accurately. However, if a leak detector is not available an approximate source can be found by applying soap solution to suspect area. To test for leaks in the high pressure side of the system i.e. from the compressor output to the orifice tube, 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.

Tightening Leaking Hoses ! 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

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.

K A

L

Hoses are used to connect the inlets and outlets of the compressor, condenser, orifice tube, evaporator coil and suction accumulator and at bulkhead connectors above and below the cab floor. If leakage is detected from a hose connector, 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.

S257701

9803/3270

Issue 2*

Section B 14 - 21

Body & Framework

Section B

Air Conditioning

14 - 21

Blower Motor Removal 1

Disconnect the battery.

2

Loosen and remove the side console screws A and remove side console B.

3

Loosen and remove bottom console screws C and remove the bottom console D.

4

Disconnect the electrical connector to the heater blower.

5

Loosen and remove bolts E.

6

Carefully remove the heater assembly F from its housing.

Replacement Replacement is a reversal of the removal procedure, make sure that the seal located between the housing and heater is in good condition - replace if necessary. Note: The heater assembly is of a modular design. This enables the air conditioning evaporator matrix to be housed next to the standard heater matrix. Complete removal of the air conditioning unit will require the refrigerant to be drained from the system.

B

A C

A A A

C D C S210343

E

F S257790

9803/3270

Issue 1

Section B 14 - 22

Body & Framework

Section B

Air Conditioning

14 - 22

Pressure Switches The 12V supply is fed to the compressor clutch field coil through three switches in series; 1) the manual ON/OFF switch F; 2) a low pressure switch K; 3) a high pressure switch L. The low pressure switch requires a minimum refrigerant charge level to close its contact. The high pressure switch requires the charge level to remain below the maximum limit to keep its contact closed.

Removal and Replacement

! 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 Both pressure switch contacts must be closed for the compressor clutch to operate. If the compressor clutch will not operate when air conditioning is selected, the fault may be either electrical or system pressure.

1

Disconnect the electrical connections and unscrew the pressure switch.

Replacement High Pressure Switch Testing 1

Switch off the engine and disconnect the electrical connector to the high pressure switch L.

2

Fit a link wire between the two terminals on the high pressure switch harness connector.

3

Switch on the engine and the air conditioning system, if the system operates the high pressure switch is faulty replace it with a new one. If the system does not operate continue to test the Low Pressure Switch.

Note: The high pressure switch has a blue body, the low pressure switch has a white body. 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.

Low Pressure Switch Testing 1

Switch off the engine and disconnect the electrical connector to the low pressure switch K.

2

Fit a link wire between the two terminals on the low pressure switch harness connector.

3

Switch on the engine and the air conditioning system, if the system operates the low pressure switch is faulty replace it with a new one. If the system does not operate check all electrical connections, fuses etc.

F

A

L

K

S257701

9803/3270

Issue 1

Section B

Body & Framework

Section B

Air Conditioning

14 - 23

14 - 23

Condenser Coil It is likely that over a period of time, because of the machine's working environment, the airflow around the condenser coil B 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.

A

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 coil. Condenser Coil Cleaning Take care not to damage the condenser fins or tubes. Damaged fins must be straightened out to ensure a good airflow through the coil. The condenser is located at the front of the machine, behind the nose grille A. 1

Park the machine on firm, level ground. Lower the backhoe and loader to the ground. Remove the starter key.

2

Remove the front grille fixing screws. Use compressed air or low pressure water to backflow through the coil fins. Take care not to damage the fins.

3

Run the air performance.

conditioning

and

check

S257800

cooling

B

S257701

9803/3270

Issue 1

Section B

Body & Framework Air Conditioning

14 - 24

Section B 14 - 24

Adjusting the Air Conditioning Compressor Drive Belt ! 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

! WARNING Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5

1


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

C S209393

9803/3270

Issue 1

Section B

Body & Framework

Section B

Hydraulic Tank

15 - 1

15 - 1

Removal and Replacement Removal

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.

Replace the tank by reversing the removal procedure. If a new tank is being fitted, remove the battery box from the old tank and fit to the new tank. Apply JCB Threadlocker and Sealer to drain plug B.

GEN-1-2

Refill with clean hydraulic oil as specified, see Lubricants and Capacities in Section 3.

1

Operate the control levers to vent residual pressure.

Torque Setting

2

Disconnect and remove the battery A.

Item B

3

Remove the filler cap and unscrew plug B to drain the tank.

4

Unscrew bolts C attaching the battery leads cover plate.

5

Disconnect and plug the hydraulic hoses D from the rear of the tank.

6

Support the tank, then unscrew mounting bolts E and lift tank away from the machine.

Nm 100

lbf ft 73.76

kgf m 10.20

D

E C

E

E

D A

E

D

B A374050

9803/3270

Issue 1

Section C

Electrics

Section C

i

i

Contents

Page No.

Technical Data General Electrical Data Fuse Identification (Except 3CXE, 214E) Relay Identification (Except 3CXE, 214E) Fuse Identification - 3CXE, 214E Relay Identification - 3CXE, 214E Fuse Identification - Servo Command Relay Identification - Servo Command Fuse Identification - 214Se Relay Identification - 214Se Fuse Identification - From Serial No. 495455 Relay Identification - From Serial No. 495455 Relay Identificatioon - Autoshift only Relay Identificatiom - Powershift transmission - From Serial No. 495455 Relay Identification - Syncro shuttle transmission - From Serial No. 495455 Link Box Fuses Bulbs

1-1 1-2 1-3 1-4 1-4 1-5 1-5 1-6 1-6 1-7 1-7 1-8 1-8 1-8 1-9 1-9

Test Methods Use of Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity How to Test a Diode or Diode Wire

2-1 2-3 2-3 2-3 2-4

Psion Workabout Introduction of Autoshift Transmission Loading JCB Supplied Psion Software Onto The Workabout - Downloading Psion Programs To The Workabout - Starting Link From The Psion Command Processor - Disabling Link - Psion Connection To The Information Display Centre - Powershift Auto Diagnostic And Fault Finding Fault Finding Servo Command Fault Finding * Brake Light Switch Adjustment

5-1 5-1 5-2 5-3 5-5 6-1 7-1

9-1

Parking Brake Switch Adjustment

10 - 1

Speed Sensor - Testing

11 - 1

Servo Command Fuse and Relay Panel - Removal and Replacement

12 - 1

Circuit Diagrams & Component Lists Basic Machine (2WS) Circuit Options and Variations - Powershift (PS700) Transmission & Steer Circuit (AWS Machines Only) - Powershift (PS700) Transmission (2WS Machines Only) - Steer Circuit for 3CX 4x4x4 Machines - 3CXE (214E Series 3) Machines Only - 214e Series 4 Machines Only 9803/3270

4-1

18 - 1 18 - 5 18 - 7 18 - 7 18 - 9 18 - 12 Issue 9*

Electrics

Section C

Section C

ii

ii

Contents

Page No.

- Autoshift Transmission (2WS Machines Only) - Autoshift Transmission (AWS Machines Only) - Powershift (PS750) Transmission & Steer Circuit (AWS Machines Only) - Powershift (PS750) Transmission (2WS Machines Only) - Steer Circuit for 3CX 4x4x4 Machines Auxiliary Electrical Options - Hand Held Tools - Dedicated Quick Hitch - Pole Planter - Smooth Ride System (SRS) - Hammer - Hand Held Tools (Variable Flow Pump) - Powershift (PS750) 2/4WD Powered ON (Germany) - Power Sideshift with Hammer Circuit - Servo Command Pilot Circuit * Basic Machine From Serial Number 495455 To 499999 And From 920000 Transmission And Steering From Serial Number 495455 Options From Serial Number 495455 Autoshift Transmission From Serial Number 495455 Auxiliary Electrical Options From Serial Number 495455 Servo Command Pilot Circuit From Serial Number 495455

9803/3270

18 - 15 18 - 17 18 - 19 18 - 21 18 - 21

18 - 23 18 - 23 18 - 23 18 - 23 18 - 24 18 - 24 18 - 25 18 - 25 18 - 26 19 - 1 19 - 5 19 - 7 19 - 9 19 - 11 19 - 13

Batteries Safety Specific Gravity Test Battery Testing

20 - 1 20 - 2 20 - 2

Wiring Harness Repair Harness Repair Introduction Tools Required Procedure

25 - 1 25 - 1 25 - 1

Starter Motor Starting Circuit Test Removal and Replacement Dismantling Service and Renewal Assembly

38 - 1 38 - 4 38 - 4 38 - 4 38 - 4

Alternator General Description Service Precautions Charging Test Removal and Replacement Dismantling and Assembly Dismantling and Assembly (Magneti Marelli Type)

39 - 1 39 - 1 39 - 1 39 - 2 39 - 2 39 - 4

Harness Location Cab and Chassis Servo Command Cab and Chassis - All Later Machines

40 - 1 40 - 2 40 - 3

Issue 6*

Section C

Electrics

Section C

Technical Data

1-1

1-1

General Electrical Data System Type

12 Volt, negative earth

Battery (Heavy Duty) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)

550

- Reserve capacity (minutes) for 25 amp load

220

Battery (Temperate) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F)

410

- Reserve capacity (minutes) for 25 amp load

170

Electronic Control Unit Shift points Hz

449/05401

2nd to 3rd

3rd to 4th

693

1467

4th to 3rd 1304

3rd to 2nd

2nd to 1st

570

326

Note: The part number and ECU settings can be verified and checked on the Psion Workabout. * Alternator 2WS

65 Amp nominal output

4WS

72 Amp nominal output

4WS (air conditioning or ServoPlus builds)

85 Amp nominal output 90 85 80 75

Max load

70 65 60 55 50

Output amps

45 40 35 30 25 20 15 10 5

0

85A

500

Tick over

0 1000

1500

2000

2500

3000

Engine speed rpm

65A 72A

A323770 A323770

9803/3270

Issue 3*

Section C

Electrics

Section C

Technical Data

1-2

1-2

! 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 9). Note that all the fuses are shown (including optional equipment fuses). Your machine may not be equipped with all the fuses shown on this page.

Fuse Identification (Except 3CXE, 214E) COLUMN 'A' Fuse Rating 1 Hydraulic Auxiliary, Smooth Ride System 10 Amp 2 Fuel pump solenoid (engine stop) 5 Amp 3 Indicators 7.5 Amp 4 Steer mode, proximity switches 7.5 Amp 5 Gearbox Control, Transmission 10 Amp 6 Powered rear window 20 Amp 7 Brake lights 5 Amp 8 4WD (automatic brake) 3 Amp 9 Left hand sidelights 3 Amp 10 Right hand sidelights 3 Amp COLUMN 'B' Fuse Rating 1 Instruments, buzzer 5 Amp 2 Front Horn, front wiper/washer 15 Amp 3 Rear horn 7.5 Amp 4 Heated seat, cigar lighter, face level fan 15 Amp 5 Rear wiper/washer 5 Amp 6 Brake switch 10 Amp 7 Rear work lights 25 Amp 8 Headlights 20 Amp 9 Front work lights 25 Amp 10 Spare COLUMN 'C' 1 Fog light 2 Main lights 3 Hazard lights 4 Beacon, interior light 5 Radio 6 Thermostart 7 Heater 8 Ignition relay coils 9 Main Beam 10 Dip Beam

9803/3270

Fuse Rating 3 Amp 7.5 Amp 15 Amp 10 Amp 5 Amp 20 Amp 30 Amp 3 Amp 15 Amp 15 Amp

10

9

8

7

6

5

4

3

2

1

5A

10A

4W

3A

3A

3A

A 5A

20A 10A 7.5A 7.5A

R B 25A 20A 25A 10A

5A

15A 7.5A 15A

5A

0

15A 15A

C 3A

30A 20A

5A 10A 15A 7.5A 3A A276790

A A333470

Issue 3

Electrics

Section C

Section C

Technical Data

1-3

1-3

The relays and fuses are located in the side console underneath cover A. Note that all the relays are shown (including optional equipment relays). Your machine may not be equipped with all the relays shown on this page.

Relay Identification (Except 3CXE, 214E) * 21 Auto Hydraulic Speed Control (HSC)

1

Ignition

2

Neutral Start

22

Reverse High/Low Ratio ➀

3

Indicators

23

Drive (Layshaft/Mainshaft) ➀ Driveshaft Interlock ➀

4

Ignition

* 24

5

Heater

25

4 Wheel Steer ➂

6

Transmission Dump

26

2 Wheel Steer ➂

7

Hydraulic Speed Control (HSC)

27

Hammer Circuit

8

Forward Drive

28

Steer Relay 1 ➂

9

Buzzer

29

Steer Relay 2 ➂

10

Parking Brake

30

Auxiliary Attachment (Jaw)

11

Reverse Drive

12

Reverse Horn

13

Front Work Lights

14

Worklights (Italian, German requirement only)

15

Lights

16

Rear Work Lights

17

Intermittent Wash/Wipe

18

All Wheel Braking (standard machines)

18

Reverse alarm (autoshift machines)

19

Forward High/Low Ratio ➀

20

2 Wheel Drive ➁

ﬁ

ﬂ

‡

°

·

‚

➀ ➁ ➂

Powershift Machines Only All Wheel Steer Machines Only 3CX 4x4x4 Machines Only - not applicable to N.Am.

1

4 7

0

£

2

5 8

!

$

3

6 9

@

%

¤

^

(

&

)

‹

*

⁄

›

AUTO

R A260443

9803/3270

Issue 4*

Electrics

Section C

Section C

Technical Data

1-4

1-4

Fuse Identification - 3CXE, 214E

Relay Identification - 3CXE, 214E

The relays and fuses are located in the side console underneath cover A.

1 2 3 4 5 6 7 8 9 10 11 12

COLUMN 'A' Fuse Rating 1 Hydraulic Auxiliary, Smooth Ride System 10 Amp 2 Fuel pump solenoid (engine stop) 5 Amp 3 Indicators 7.5 Amp 4 Steer mode, proximity switches 7.5 Amp 5 Gearbox Control, Transmission 10 Amp 6 Powered rear window 20 Amp 7 Brake lights 5 Amp 8 4WD (automatic brake) 3 Amp 9 Left hand sidelights 3 Amp 10 Right hand sidelights 3 Amp

Ignition Neutral Start Indicators Ignition Front Work Lights Transmission Dump Rear Work Lights Forward Drive Buzzer Parking Brake Reverse Drive Reverse Horn

COLUMN 'B' Fuse Rating 1 Instruments, buzzer 5 Amp 2 Front horn, front wiper/washer 15 Amp 3 Rear horn 7.5 Amp 4 Heated seat, cigar lighter, face level fan 15 Amp 5 Rear wiper/washer 5 Amp 6 Brake switch 10 Amp 7 Rear work lights 25 Amp 8 Headlights 20 Amp 9 Front work lights 12 Amp 10 Spare COLUMN 'C' 1 Fog light 2 Main lights 3 Hazard lights 4 Beacon, interior light

10

9

8

7

6

Fuse Rating 3 Amp 7.5 Amp 15 Amp 10 Amp

5

4

3

2

1

4W

3A

3A

3A

A 5A

20A 10A 7.5A 7.5A

5A

10A

A

R B 25A 20A 25A 10A

5A

15A 7.5A 15A

5A

0

15A 15A

C 3A

30A 20A

A333470

5A 10A 15A 7.5A 3A A276790

7

0

8

!

9

@

0 1

0 4

0 2

5

F R

3

6

P

R A265070

9803/3270

Issue 3

Section C

Electrics

Section C

Technical Data

1-5

1-5

Fuse Identification - Servo Command

Relay Identification - Servo Command

The relays and fuses are located in the side console underneath cover A.

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25

1 2 *3 *4 5 6 7 8 9 10

Spare Spare Left Amplifier Right Amplifier Right hand pilot valve Left hand pilot valve Return to dig Main feed Servo isolation switch Change over solenoids

A

Fuse Rating 5 Amp 5 Amp 5 Amp 5 Amp 1 amp 10 Amp 3 Amp 15 Amp

Ignition Front seat Front mode changeover Rear seat Rear mode changeover Right hand joystick proportional switch supply Right hand amplifier supply Front auxiliary supply Hammer interlink Stabiliser isolate Left hand amplifier supply Sweeper/Clam changeover Pilot valves changeover Auxiliary/Clam 2 changeover Auxiliary/Clam 1 changeover Stabiliser/Clam 2 changeover Stabiliser/Clam 1 changeover Stabiliser/Auxiliary 1 changeover Stabiliser/Auxiliary 2 changeover Stabiliser lower changeover Stabiliser raise changeover Stabiliser lower/mode changeover Stabiliser raise/mode changeover Dump interlink (autoshift only) Spare

R11

R10

R8

R9

R13

R12

R6

R7

R15

R14

R4

R5

R17

R16

R2

R3

BUZZER

R1

10 9 8 7 6 5 4 3 2 1

R18

R20

R22

R24

R19

R21

R23

R25

A334090

9803/3270

Issue 3*

Electrics

Section C

Section C

Technical Data

1-6

Fuse Identification - 214Se

1-6

Relay Identification 214Se

COLUMN 'A' 1 Hydraulic auxiliary 2 Fuel pump solenoid (engine stop) 3 Turn signals 4 Spare 5 Gearbox control, Transmission 6 Spare 7 4WD (automatic brake) 8 Brake lights 9 Right hand sidelights 10 Left hand sidelights

Fuse Rating 5 Amp 5 Amp 7.5 Amp

COLUMN 'B' 1 Instruments, buzzer 2 Front horn, front wiper/washer 3 Spare 4 Auxiliary power socket 5 Rear wiper/washer 6 Brake switch 7 Rear work lights 8 Headlights 9 Front work lights 10 Beacon

Fuse Rating 5 Amp 15 Amp

COLUMN 'C' 1 Spare 2 Dip beam 3 Lights 4 Hazard 5 Face level fan 6 Radio 7 Thermostart 8 Heater 9 Ignition relay coils 10 Main beam

Fuse Rating

A B C D E F G H J K L M N

10 Amp 3 Amp 5 Amp 3 Amp 3 Amp

4 Wheel brake Lights Turn signals Reverse drive Forward drive Front work lights Parking brake Transmission dump Rear work lights Neutral start Ignition 1 Buzzer Ignition 2

20 Amp 15 Amp 10 Amp 25 Amp 20 Amp 25 Amp 10 Amp

15 Amp 7.5 Amp 15 Amp 10 Amp 1 Amp 20 Amp 30 Amp 3 Amp 15 Amp

A

B

C

D

E

F

G

H

J

4W

4W

10

9

8

7

6

5

4

3

2

1

4W

A A 3A 3A 3A

5A 5A 3A

10A 10A

7.5A 7.5A

5A 5A 5A 5A

K

B B 10A 15A 20A 10A 25A 25A 20A 20A 25A 10A 15A

L

15 5A 5A 15A 1

M

1

N

C 15A 15A 3A 3A 30A 20A 1A 10A 15A 15A 7.5A 7.5A 15A 15A

2

345740

9803/3270

817/16774

2

345741

Issue 2

Electrics

Section C

Technical Data

1-7

Fuse Identification - From Serial No. 495455 Fuse Rating

* COLUMN ‘A’ 1 2 3 4 5 6 7 8 9 10

Hydraulic auxiliary Fuel pump solenoid (engine stop) Direction indicators Steer mode proximity switch Gearbox control, Transmission Spare Brake lights 4 wheel drive (automatic brakes) Left hand side lights Right hand side lights

10 Amp 5 amp 7.5 amp 7.5 Amp 10 Amp 5 Amp 3 Amp 5 Amp 5 Amp

* COLUMN ‘B’ 1 2 3 4 5 6 7 8 9 10

Section C

Instruments, Buzzer Front horn, Front washer/wiper Rear horn Heated seat, Cigar lighter, Face level fan Rear wiper/wash Brake switch Return to dig enable Rear working lights Headlights Front working lights

5 Amp 15 Amp 7.5 Amp 15 Amp 10 Amp 10 Amp 5 Amp 25 Amp 20 Amp 25 Amp

1-7

* Relay Identification - From Serial No. 495455 A B C D E F G H J K L M N P Q R S T U

Heater Direction indicator Ignition Ignition Neutral start Buzzer Intermittent wash/wipe switch Rear working lights Front working lights Rear horn 2/4 wheel braking Engine run Auxiliary (jaw bucket) Reverse alarm Hydraulic speed control Hammer Main lights 2 wheel drive Parking brake

* COLUMN ‘C’ 1 2 3 4 5 6 7 8 9 10

Lights Hazard light Beacon, Interior light Radio Thermostart Heater Ignition relay coils Main beam Fog light Dip beam

7.5 Amp 15 Amp 10 Amp 5 Amp 20 Amp 30 Amp 3 Amp 15 Amp 3 Amp 15 Amp

P

Q

M

N

S

R

G

F

K

L

H

U

T

E

J

D

C

B

A A356072

A357830 A356071

10 9 8

7 6 5

4 3 2 1

4WD

A

C

B 10 9 8

9803/3270

7 6 5

4 3 2 1

10 9 8

7 6 5

4 3 2 1 Issue 3*

Section C

Electrics

Section C

Technical Data

1-8

Relay Identification - Autoshift Only

1-8

Relay Identification - Powershift * Transmission From Serial No. 495455

The relays and fuses are located in the side console underneath cover A. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Ignition Neutral Start Indicators Ignition Heater Parking Brake Hydraulic Speed Control Auxiliary Attachment (Jaw) Buzzer Auto Hydraulic Speed Control Hammer Reverse Horn Front Working Lights Working Lights (Italian, German requirement only) Lights Rear Working Lights Intermittent Wash/Wipe Reverse Alarm

1 2 3 4 5 6 7 8

Spare Reverse drive Reverse (High/Low ratio) Forward (High/Low ratio) Transmission dump Forward drive Driveshaft interlock Drive (Layshaft/Mainshaft)

2 6

1 5

3 7

4 8

A359330

Relay Identification - Syncro Shuttle * Transmission From Serial No. 495455 1 2 3 4

A

Transmission dump Forward drive Spare Reverse drive

A333470

1

4

7

0

£

^

2

5

8

!

$

&

3

6

9

@

%

*

A334100

9803/3270

1 3

2 4

A357840

Issue 2*

Section C

Electrics

Section C

Technical Data

1-9

Link Box Fuses

1-9

Bulbs

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.

Head lights - main/dip †

45/37.5W

Front Lights ††

55W Halogen

Work lights

55 Halogen (front & rear)

Front side lights †

5W

1

Hazard warning lights, Beacon, Lights

30 Amp

Tail/stop lights

5/21W

2

Wash/Wipe, Transmission, Indicators

50 Amp

Fog light †

21W

Direction turn indicators

21W (front & rear)

3

Work lights, Fog Lights, Brake lights

50 Amp

Instruments

1.2W

4

Ignition, Heater, Thermostart

50 Amp

Warning lights

3W

Number plate light †

1 x 5W

Interior light

10W

Beacon †

70W Halogen

† Note: These items are not applicable to North America †† Note: These items are applicable to North America only

B

S254320

1

2

3

4

9803/3270

A254310

Issue 1

Section C

Electrics

Section C

Test Methods

2-1

2-1

Use of Multimeter These instructions are intended to cover the use of the recommended multimeters.

A

OFF V/A

A

V/A

C

B

C

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 " ".

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.

9803/3270

Issue 1

Section C 2-2

Electrics

Section C

Test Methods

2-2

S153070

9803/3270

Issue 1

Section C 2-3

Electrics

Section C

Test Methods

2-3

Measuring DC Voltage On the FLUKE 85 Turn the switch to position B. On the AV0 2003 Move the right slider switch to position A, and the left hand slider switch to the appropriate range. 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.

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. On the FLUKE 85 Turn the switch to position C and check that the 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 . Touch the meter lead probes together and press the REL ³ key on the meter to eliminate the lead resistance from the meter reading. On the AV0 2003 Move the right hand slider switch to position B, and the left hand slider switch to the appropriate Ohms ( ) range. On an analogue meter Move the dial to the appropriate Ohms ( ) range.

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. 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. 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. On an analogue meter Turn the dial to the lowest Ohms ( ) 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.

9803/3270

Issue 1

Section C 2-4

Electrics Test Methods

Section C 2-4

How to Test 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. 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. 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. 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 , 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 , if it reads less than this the diode is faulty.

9803/3270

Issue 1

Section C

Electrics

Section C

Psion Workabout

4-1

4-1

INTRODUCTION OF AUTOSHIFT TRANSMISSION

1)

INTRODUCTION: The Autoshift system comprises a Powershift gearbox controlled by an Electronic Control Unit (E.C.U.). This provides the operator with an automatic gear change in 3rd and 4th when roading and 1st, 2nd and 3rd manual gear selection, for onsite work. In addition, a kickdown function has been incorporated. This allows the operator to temporarily select a lower gear during site work or to select 2nd gear on the road if conditions demand this.

2)

KEY COMPONENTS: Gearbox: The existing 4 speed, 40 kph Powershift gearbox has a speed sensor fitted to detect the speed of rotation of the output shaft. This information provides road speed information to the E.C.U. (see below). E.C.U.: The E.C.U. is a new component. It is a Solid State, microprocessor-based, electronics "black box", mounted inside the cab under the right-hand-side mouldings. Based upon data supplied from the column switch, kickdown button, foot throttle (see Controls/Instrumentation below), parkbrake switch, transmission dump switch and the speed sensor, the E.C.U. controls the gear selection solenoid valves on the gearbox. Controls/Instrumentation: The gear selection is selected on the Forward, Neutral, Reverse (FNR) lever rotary switch but the "4" position is changed to "A" for "Automatic" mode. Positions "1", "2" and "3" remain as current, manually selecting those gears. A micro-switch is operated by the foot throttle pedal. This tells the E.C.U. whether throttle is selected or not. A foot-operated kickdown button is located on the cab floor to the left of the brake pedal. When in a manually-selected gear, if the kickdown is pressed, the next lowest gear is selected. By pressing kickdown again, the gearbox will revert to the previous higher gear. When in automatic mode at slow speeds, pressing kickdown will engage 2nd gear. 3rd gear is re-engaged either by a second press of the kickdown button or automatically when the machine reaches the preprogrammed speed for a 2nd to 3rd gear change. The warning buzzer and red warning light on the front instrument panel will be activated if a gear selection is made which is not allowed by the E.C.U. software (see System Logic). This comprises a double-bleep which will continue either until the selection conditions are met, or the request is de-selected. For a non-allowed kickdown request, the buzzer will double-bleep only once, at the time of the request. In the case of a speed sensor failure when in Automatic mode, the buzzer will double-bleep continuously until the ignition is turned off. When the machine is re-started, the E.C.U. will be in a "get you home" mode (see System Logic,).

3)

SYSTEM LOGIC There are two modes of operation, Automatic and Manual. Automatic mode is selected via the FNR lever rotary switch "A" position, and Manual mode by selecting a specific gear, "1", "2" or "3". The E.C.U. will not allow gear changes to occur in either Automatic or Manual modes if outside the pre-programmed conditions. The following description explains the system logic. Automatic mode: • When position "A" is selected, the transmission will change gear between 3rd and 4th automatically according to road speed. This mode is recommended for roading only. On-site, manual gear selection is recommended. Note: The system does not sense load on the transmission. • • • •

A change in direction can be made at any time. However, 4th gear in reverse is not available. The foot throttle switch prevents the transmission changing from 3rd to 4th when travelling downhill with foot off the throttle, providing engine braking. Note that if the transmission is already in 4th gear, the throttle switch has no effect. If 4WD has been selected for the machine, 4WD is disengaged automatically in Automatic mode, except when 2nd gear is engaged by kickdown, then 4WD is enabled for improved traction. When braking, 4WD is engaged automatically. On the 3CX, this may be cancelled via the brake mode switch if 2 wheel braking has been selected.

9803/3270

Issue 1

Section C

Electrics

Section C

Psion Workabout

4-2

4-2

Manual mode: • 1st, 2nd and 3rd gears are selected in the normal way on the column switch. • The E.C.U. does not allow downshifts above certain speeds. If attempted, a double-bleep will sound and the transmission remains in its current gear until the speed has reduced sufficiently to allow a downshift to occur. Upshifting is not speed limited. • A change in direction can be made at any time. • If 4WD is selected for the machine, 4WD is maintained in all 3 gears. Kickdown facility - Manual mode • When in 2nd or 3rd gear manual mode, pressing the kickdown button will result in a gear change to the next lowest gear. • Kickdown operation is subject to the same pre-programmed speed limits as downshifts. If a non-allowed kickdown is requested, kickdown will not occur. The buzzer will sound a double-bleep. Note that the E.C.U. does not retain the kickdown request in its memory, so kickdown will have to be re-selected once the machine speed has reduced. • The transmission will revert to the original gear either by selecting a directional change on the FNR lever or by pressing the kickdown button again. Kickdown facility - Automatic mode • When in 3rd gear automatic at slow speed, pressing the kickdown button will result in a gear change into 2nd. In 4th gear automatic, kickdown is not allowed and pressing the kickdown button will not sound the warning buzzer. • Kickdown operation is subject to the same pre-programmed speed limit as manual downshift 3rd to 2nd gear. If a non-allowed kickdown is requested, kickdown will not occur. The buzzer will sound a double-bleep. Note that the E.C.U. does not retain the kickdown request in its memory, so kickdown will have to be re-selected once the machine speed has reduced. • The transmission will change back up to 3rd gear when the machine speed reaches the pre-programmed limit. This speed has been set near maximum speed in 2nd gear so that 3rd gear is not selected too early, for example during a hill climb. The operator can reselect 3rd gear himself, overriding the automatic speed setting, by pressing the kickdown button. Note: Care is to be taken when downshifting, either by kickdown or manual selection on the column switch. It is recommended that downshifting is not requested at high speed, relying on the downshift protection system to avoid sudden deceleration. The downshift protection system is to reduce loads on the transmission, thereby improving its life, and is not to be used as a means of pre-selecting a downshift when slowing down. If the speed sensor fails, (see "Get you home" facility), downshift protection will not be available. Warning buzzer/light: • A double-bleep will sound for the following reasons; Kickdown or manual downshift selected when machine speed is above the pre-programmed limit. Failure of the speed sensor when in Automatic mode. In this case the buzzer will double-bleep continuously. "Get you home" facility: • If the speed sensor fails whilst roading in Automatic mode, the buzzer will start to double-bleep continuously and the transmission will remain in the current gear, irrespective of machine speed. The machine must be brought to a stop as soon as it is safe to do so and the ignition turned off. On starting the machine again, the buzzer will not sound and only 3rd gear and kickdown to 2nd gear will be available in Automatic mode. In Manual mode, all three gears will be available with kickdown. Note that there will be no downshift speed protection. Care is to be taken when downshifting with either kickdown or gear selection on the column switch. •

If the speed sensor fails whilst in Manual mode, the buzzer will not sound. All three gears will be available with kickdown but there will be no downshift speed protection. If Automatic mode is selected, only 3rd gear and kickdown to 2nd gear will be available. Again, there will be no downshift speed protection. Care is to be taken when downshifting with either kickdown or gear selection on the column switch.

9803/3270

Issue 1

Section C

Electrics Psion Workabout

4-3

Section C 4-3

Diagnostics facility: • A Sumitomo connector is provided within the right-hand side console to allow connection by the service engineer to the on-board E.C.U. fault diagnostics system.

! WARNING

If you intend to use the Psion Tester while the machine is in motion you must take all precautions to ensure the safety of yourself and others. Do not use the test equipment on the public highway. Elec 1-2

Do not use the machine with a defective or damaged speed sensor or the wrong gear will be indicated when 4th gear is selected. If the ECU has a 4th gear/speed sensor activation feature, 4th gear will not be selected, this is to prevent the operator continuing to operate the machine without downshift protection. The safety start for a machine is normally obtained from the machine relays. However, if the ECU is powered up in gear, neutral will have to be selected before drive can be obtained. The Neutral, Handbrake and Dump are input selection signals to the ECU and are shown on the Psion UNIT STATUS screen A. The ECU selections to the gearbox are displayed on screen B. The example screen A shows FORWARD, LEVER 2 (2nd gear) selected and on screen B the ECU is selecting Neutral because the DUMP switch is being operated.

A

9803/3270

B

Issue 1

Section C

Electrics

Section C

Psion Workabout

5-1

5-1

Loading JCB-supplied Psion Software onto the Workabout Install PsiWin application on the Dealership PC (PsiWin Users Guide) Connect the Docking Holster to the PC (Refer Psion Workabout User Guide) Insert Workabout into Docking Holster (Refer Psion Workabout User Guide)

A

Downloading Psion Programs to the Workabout

Run Link program on Workabout from: Command Processor screen refer step 2 Run the PsiWin Psion Manager on the PC (Refer Psion Workabout User Guide) Select the ‘Copy...’ option from the ‘File’ menu Specify the ‘From’ and ‘To’ drives as follows: ‘From’ Press ‘Browse’ In the ‘Computer’ window, select ‘PC’ In the ‘Drives’ window, select: ‘D:’ if installing from CD-ROM ‘A:’ if installing from floppy disk (note that drive assignments may differ on your machine) In the ‘Directories’ window, double-click on the ‘psion’ folder and then double-click on the required language directory (ie ‘english’, ‘french’, ‘german’, ‘spanish’, ‘italian’, or ‘portuguese’) In ‘File Name’ window, type ‘*.img’ Click on ‘OK’ to set this as the drive to read the program files from ‘To’ Press ‘Browse’ In the ‘Computer’ window, select ‘PSION’ In the ‘Drives’ window, select ‘Internal [RAMDRIVE]’ In ‘File Name’ window, type ‘*.*’ Click on ‘OK’ to select this as the drive to write program files to Click on ‘OK’ to copy files between the PC and the Psion If asked ‘Confirm File Replace’, click on ‘Yes to All’ When all programs are loaded. at ‘M>’ prompt (on Psion) press ‘Menu’ select ‘Remote Link’ (press Enter) and using left or right arrow keys switch to ‘Off’. (This disables Link on Workabout, refer step 3)

B

Starting Link from the Psion Command Processor

1

After connecting the Psion Press

On/Esc

The Psion display should be the System Screen. If not, then press

Ctrl

Del

at the same time.

This resets the Psion and takes approximately 5 seconds. Press

2

Menu

Select Command processor option using Press

9803/3270

Enter

Issue 1

Section C


5-2 3

5-2

Display shows M> prompt. Press

4

Section C

Menu

Select Special using Select Remote link using Press

5

Enter

Remote link settings screen: Off Select Remote Link option using To set Remote link On use To activate Remote link press

Enter

Note: If a beep is sounded there is an error. Check all connections.

6

Remote link settings screen: On

After all programs have been copied ‘Disable Link’ see below.

C

Disabling Link

1

Navigate to Remote link screen as described in procedure B. Set Remote link OFF using Press

2

Enter

This screen is displayed when the Remote link is Off.

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Issue 1

Section C


5-3 D

Psion Connection to the Information Display Centre (IDC)

1


Section C 5-3

On/Esc


Ctrl

Del

at the same time.

This resets the Psion and takes approximately 5 seconds. Press 2


3

Menu

Enter

Display shows M> prompt. Type ‘IDC’ or ‘idc’ Press

4

Enter

This will run the IDC program, then press any key. At the next screen pressMenu

to display options.

Service Perform Service

Turns OFF service indicator spanner and updates service history in IDC when dealer and Engineer codes are entered.

Save History To Disc

Retrieves machine service history and saves to Psion internal drive.

Restore History From Disc

View saved history file.

PDI

Stores PDI information: Entered at PDI. Dealer Account number. Engineer identification number.

Installation

Stores installation information: Entered when machine is Installed. Dealer Account number Engineer identification number

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Issue 1

Section C 5-4


Section C 5-4

View VIN

Displays machine VIN number (eg. SLP3CXTSVE0469999 (17 digits))

PIN History

Displays machine PIN number (eg. 0469999 (7 digits)) Displays machine history Ex works date PDI date Installation date Details of last two services Displays machine hours. Displays number of Services carried out. Displays IDC product information.

Engine Hours No Of Services Product Information Commissioning

IMPORTANT NOTE: Service mode must be set prior to entering VIN number. Time *VIN

*Engine Hours *No Of Services Service Params †Service Mode

Allows time to be set from Psion Workabout internal clock without using buttons (Refer Psion Workabout user guide to reset internal clock). VIN number already entered by JCB production on new machines. When a new IDC unit is fitted in the field the VIN number can be entered by dealer personnel. Number must be entered twice to prevent errors (once it has been accepted it can not be removed/replaced.) Sets engine hours, can only be set once from zero. Allows number of services to be set, can only be set once from zero. Disabled for service personnel. To change method of turning OFF service indicator light. ENABLE (Dumb IDC) - Allow service indicator light to be turned OFF using clock buttons. Select clock to 24 hour and key 0348 to extinguish light. DISABLE (Intelligent IDC) - Service indicator light can only be turned OFF using Psion.

* used only when a new IDC unit is fitted to replace the original IDC unit. † replacement IDC’s are supplied as ‘Dumb’ units, use ‘service mode’ to disable. Special Delete History File Delete All Histories EXIT

9803/3270

Deletes service history file from Psion Workabout internal drive. Deletes all history files on Psion Workabout internal drive Quits IDC program.

Issue 2

Section C


5-5 E

Section C 5-5

Powershift Auto Diagnostic and Fault Finding

If the Psion should lock up at any time during the use of the software, exit the program by pressing Ctrl at the same time. 1


On/Esc


Ctrl

Del

at the same time.

This resets the Psion and takes approximately 5 seconds. Press Menu 2


3

Enter

Display shows M> prompt. Type ‘AUTOPS’ or ‘autops’ This will run the AUTOPS program. Press

4

Enter

This screen allows the user to verify that the correct ECU and Psion software are being used. Turn the ignition switch to ON Press

5

Enter

If this screen appears: Check wiring from Psion to ECU Check power is on to the ECU Check the remote link is OFF, see B steps 5 and 6. Press On/Esc to QUIT the program.

6

ECU displays its details. Allows the user to know which ECU is fitted without having to physically inspect the ECU label. Press

9803/3270

Enter

to Continue or On/Esc

to Exit program.

Issue 1

Section C


5-6 7

5-6

This screen is displayed if the ECU and software being used are incompatible. Press On/Esc

8

Section C

to Exit program.

This screen shows the ECU software settings but does not allow the user to make any changes. These settings determine the downshift protection, gear lever set up, any kickdown timer used and autoshift speeds. This information can be useful for diagnosing any suspected faults. Press

9

Enter


to Exit program.

The ECU can detect faults with solenoids and wiring and only displays this screen if a fault is found. On this screen example the ‘Reverse High’ is highlighted. The Psion can detect either an open or short circuit in the solenoid or electrical connections to the solenoid. Check wiring to the solenoids Check solenoids Press

10

Enter


to Exit program.

If ‘Continue’ is selected from the window at step 9 and the fault has not been rectified this warning message is displayed. This may result in missing gears. Press

11

to Continue.

If the fault is rectified the highlighting disappears. Press

12

On/Esc

Enter


to Exit program.

If Continue is selected at step 11 and the fault has been rectified this screen is displayed. Press

9803/3270

On/Esc

to Continue.

Issue 1

Section C


5-7 13

Section C 5-7

This is the next screen to be displayed, if there are no solenoid connection faults this screen would be displayed after step 8. This is the main diagnostic screen and is the final destination of the software. The previous screens can not be recalled, exit the program and restart if they are required again. In this example the input lever/switch selection is FORWARD and LEVER 1, the ECU is selecting Forward 1st. Press

On/Esc

to Exit the program.

Operating the various controls in the cab will change the display accordingly. Some examples are shown below. EXAMPLE 1 This example shows the input selection is FORWARD and 4th gear automatic has been selected on the twist switch LEVER 3 and LEVER 4. The THROTTLE switch signal must be highlighted to allow automatic change up at the pre-determined SPEED FREQUENCY. This feature prevents higher gears being selected when the machine is going downhill and gathering speed. EXAMPLE 2 This example shows the input selection is NEUTRAL, forward/reverse lever in the neutral position, and LEVER 1, 1st gear selected on the twist switch and the ECU is selecting Neutral.

EXAMPLE 3 This example shows the input selection is FORWARD and LEVER 2, 2nd gear selected on the twist grip but the ECU is selecting Neutral as the momentary DUMP switch is being pressed.

EXAMPLE 4 This example shows the input selection is FORWARD and LEVER 2, 2nd gear selected on the twist grip but the ECU is selecting Neutral as the HANDBRAKE is applied. This condition will result in the machine warning alarm sounding a continuous tone.

EXAMPLE 5 This example shows the input selection is FORWARD and LEVER 2, 2nd gear selected on the twist grip but the ECU is selecting Forward 1st as the KICKDOWN has been activated by pressing the momentary kickdown switch.

9803/3270

Issue 1

Section C

Electrics

Section C

Fault Finding

6-1

Fault Finding Contents

Introduction Page No.

Introduction No drive on power up No drive and continuous warning buzzer No drive Missing gears No 4th gear (4 speed machines only) Downshift protection not operating No dump No 4 wheel drive Intermittent 4 wheel drive Transmission will not downshift Lower gear than switch selected engaged Kickdown not operating Reverse will not select Psion unit will not operate

Fault No drive on power-up.

6-1

6-1 6-1 6-1 6-1 6-1 6-1 6-2 6-2 6-2 6-2 6-2 6-2 6-2 6-2 6-2

The purpose of this section is to help you trace electrical faults to a faulty unit. Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the Service Manual. To help identify circuits, refer to the electrical schematic diagrams. Refer to Section F, Fault Finding also as this section will deal with the mechanical aspect. 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 any relevant electrical checks before commencing work.

Probable Cause

Action

Blown ECU fuse.

Check ECU fuse A5

ECU mainframe connector loose.

Check connector is mating correctly with

Gear twist switch not in neutral.

Gear switch must be in neutral on power up before a gear can be selected.

ECU.

No drive and continuous warning buzzer.

Attempting to select drive with the handbrake engaged.

Release handbrake.

No drive.

Faulty gear switch.

Check switches and wiring.

Handbrake sticking.

Check handbrake assembly.

Faulty gearbox harness.

Check gearbox harness and connector for continuity.

Faulty dump input.

Check dump switch and wiring.

Faulty solenoid(s)

Check solenoid(s) and wiring.

Fault gear switch

Check switch and wiring

Low oil pressures

Check clutch pack pressures, see Section F. Check mainline pressure, see Section F.

Mechanical failure

See Section F.

Faulty speed signal

Check speed sensor and wiring. Check speed sensor installation.

Missing gears

No 4th gear (4 speed machine only)

..... continued

9803/3270

Issue 1

Section C

Electrics

Section C

Fault Finding

6-2 Fault

6-2

Probable Cause

Action

Downshift protection not operating

Faulty speed signal

Check speed sensor and wiring. Check speed sensor installation.

No dump selection

Faulty dump input

Check dump switch and wiring.

No 4 wheel drive (if fitted)

Faulty 4 wheel drive input

Check 4 wheel drive switch and wiring.

Faulty 4 wheel drive solenoid

Check solenoid and wiring.

Faulty 4 wheel drive input

Check 4 wheel drive switch and wiring.

2/4 wheel drive brake switch operating

Check brake switch and wiring.

Intermittent 4 wheel drive

Transmission will not downshift

Speed too fast for selected downshift Slow the machine.

Lower gear engaged than selected

Kickdown engaged

Check kickdown switch and wiring.

Kickdown not operating

Speed too fast to engage lower gear

Slow the machine.

Faulty kickdown input

Check kickdown switch and wiring.

Reverse will not operate

Speed too fast to reverse direction

Slow machine.

Psion will not communicate

Faulty connecting lead.

Check lead connection.

No power to ECU

Turn ignition ON. Check fuse A5. Check power supply to ECU.

9803/3270

Issue 1

Section C

Electrics Servo Command Fault Finding

7-1


Introduction Servo controls fail to operate Controls from joystick fail to operate but mode switch operates Changeover from loader to excavator controls fails to operate Left hand controls fail to operate Right hand rocker switch fails to operate (clam, extending dipper, auxilary) Left hand rocker switch fails to operate (stabiliser, auxilary) Stabilisers fail to operate Stabiliser changeover logic fails to operate

Fault Servo controls fail to operate

Controls from joystick fail to operate but mode switch operates

Changeover from loader to excavator controls fails to operate

Left hand controls fail to operate

Right hand rocker switch fails to operate (clam, extending dipper, auxilary)

7-1


9803/3270

Section C

7-1 7-1 7-1 7-1 7-1

The purpose of this section is to help you trace electrical faults to a faulty unit. Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the Service Manual. To help identify circuits, refer to the electrical schematic diagrams. Refer to Section E, Fault Finding also as this section will deal with the hydraulic aspect.

7-1 7-1 7-2 7-2

1


2


3

Make any relevant electrical checks before commencing work.

Probable Cause

Action

Blown servo fuse

Check fuses 5, 6, 8 and 9

No electrical power to left or right pilot solenoid valves

Check enable switch and wiring for continuity Check relay R1

No hydraulic pilot pressure

See Servo Command Hydraulic Fault Finding

Faulty front or rear seat proximity switch

Check adjustment and operation. Note: The indicator LED in the enable switch illuminates as the seat switches operate.

Faulty relay

Check relay R2 and R4

Blown fuse to changeover solenoid

Check fuse 10

Faulty relay

Check relay R3 and R5

No electrical power to changeover valves

Check wiring for continuity

Faulty changeover solenoid

Replace as required

Blown fuse

Check fuse 6

No hydraulic pilot pressure

See Servo Command Hydraulic Fault Finding

Blown fuse to right hand amplifier

Check fuse 4 Check supply to amplifier Note: LED on amplifier illuminates green to indicate supply

Faulty wiring between joystick and amplifier

Check signal to amplifier Note: LED on amplifier illuminates orange for signal and red for fault

Faulty wiring between amplifier and proportional solenoid on valve block

Check signal to solenoid valve The signal is a pulse width modulated 12 volt output and varies from 0 to 1.6 amps. Issue 1

Section C

Electrics

Section C

Servo Command Fault Finding

7-2 Fault Left hand rocker switch fails to operate (stabiliser, aux)

Probable Cause Blown fuse left hand amplifier

7-2 Action

Check fuse 3 As right hand rocker switch fails to operate

Stabilisers fail to operate

Stabiliser changeover logic fails to operate

9803/3270

As, right hand rocker switch fails to operate Faulty relay

Check relays R16 to R23

Issue 1

Section C

Electrics Brake Light Switch

9-1

Section C 9-1

Adjustment An improved footbrake switch has been introduced on all Backhoe machines from serial number 495500. It can be identified by a white coloured terminal block and supercedes the old switch with a green terminal block. A firmer return spring has also been introduced to eliminate brake pedal bounce. 1

With the brake pedal in the return position, screw the switch A in fully until the body touches the brake pedal lever.

2

Screw out one full turn to ensure the brake pedal lever can only engage the switch plunger and not foul the body.

3

Secure in position by tightening locknuts B.

4

Check the correct operation of the brake lights.

A B B

9803/3260

Issue 1

Section C 10 - 1

Electrics

Section C

Parking Brake Switch

10 - 1

Adjustment Note: Depending on machine type, the parking brake switch may be mounted as shown at A or B. Select the starter switch to the ON position, do not start the engine. Select either forward or reverse. Raise the handbrake to the ON position. Screw the parking brake switch C in a clockwise direction until the audible alarm sounds and the visual warning is illuminated. Lock switch C in position with lock nuts D. Release the parking brake and the audible alarm should cease and the visual alarm extinguish. For adjustment of the Parking Brake, see Section G, 'Parking Brake Caliper'.

A C D

D

B D D C

S218320

9803/3270

Issue 1

Section C

Electrics

Section C

Speed Sensor

11 - 1

11 - 1

Testing Powershift machines fitted with an electronic control unit (ECU) or a speedometer have a speed sensor A fitted. The speed sensor detects the speed of rotation of the output shaft and relays this information to the ECU. See Powershift - Assembly, SECTION F for spacer selection according to output gear ratios, number of teeth. Because the ECU requires a speed signal in order to determine the operating speed of the machine, certain gear selections will not be permitted unless the speed signal is being relayed, ie. downshift at too high a speed.

TA

B TB

A

Note: The ECU is designed to inhibit 4th gear selection if the speed sensor fails to relay a signal. So that the speed sensor can be tested without removing, a test lamp (part No. 892/00940) has been introduced. 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 lamp B as shown. 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 5 feet, make sure it is clear in front. Alternatively raise the wheels off the ground. If the sensor is operating correctly the LED will illuminate when a gear tooth passes the sender, as the speed increases the light will flash, lighting continuously at higher speeds.

4

If the LED fails to illuminate, remove the sender from the transmission, placing a clean container underneath to catch the oil.

5

With the ignition ON place a steel object such as a spanner against the sensor: Does the LED now illuminate? check

9803/3270

YES NO

S308630

- Too large a gap, check correct spacer is fitted. - Check damage to sensor from gear contact, renew as required and the correct spacer is fitted. - Check for battery voltage at pin 1 and an earth at pin 3. If the pins in the harness and connector are OK, fit a new sensor and check if OK. - If the fault is still apparent carry out a continuity check between the connector and ECU. - Repair or replace the harness as required. - Check the ECU, replace as required.

Issue 1

Section C

Electrics

Section C

Servo Command

12 - 1

12 - 1

Fuse and Relay Panel Removal

Replacement

1

Dissconnect the battery.

Replacement is a reversal of the removal procedure.

2

Remove parking brake gaiter A. Disconnect the parking brake switch electrical connector J to prevent damage to connector when removing the console.

Reconnect the battery and check the electrical circuits for correct operation.

3

Remove screws B and lift off forward console C.

4

Undo screws D and raise the panel to gain access to electrical connectors on the underside.

5

Release electrical connectors E and F, disconnect panel illumination G and earth lead H.

6

The fuse and relay panel can now be removed.

J

A C

B

G D

F E

H

9803/3270

352730

Issue 1

Section C

Electrics

18 - 1

Section C

Circuit Diagrams and Component Lists

18 - 1

Basic Machine TO PAGE C/18-4

19

61

60

143 63 5

3

9

8

1 112

140

10

116 141 6

11

57

12

13 14

15

73

20

74

145

B

B

142

144

B/N

B/O

75

76

77 106

68

56

7

4 114

113

54 16

118 105

117

69

72 146

65

17 22

110

66

21

155

24 18

67

115

23

147 149 151 175 148 150 152

70

62 71 64

111 2

A273991 (CAD 852/30214-sheet 1 issue 5)

9803/3270

Issue 3

Section C 18 - 2

Electrics

Section C


18 - 2

Basic Machine Refer to pages C/18-1 and C18-4. The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer. The remaining pages in section C/18 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 11 Hydraclamp Solenoid 12 Hydraulic Speed Control Solenoid 13 Socket (Junction Box Feed) 14 Shovel Reset Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 27 Cigar Lighter 28 Clock 29 Face Level Fan 30 Heated Seat 31 Rear Washer Motor 32 Rear Wiper Motor 33 Washer Motor 34 Front Wiper Motor 35 Horn (Front) 36 Socket (Dipper Light) 37 Beacon 38 Tracker 39 Radio 40 Heater Motor 41 Heater Resistor 42 Air Conditioning Compressor 54 Warning Buzzer 56 Electric Rear Window ECU 57 Electric Rear Window Motor

Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 66 Hydraclamp Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 69 Shovel Reset Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 78 Face Level Fan Switch 79 Heated Seat Switch 80 Rear Washer/Wiper Switch 81 Head Light Flasher Switch 82 Front Washer/Wiper Switch 83 Horn Push (Front) 84 Rear Fog Light Switch 85 Head and Side Lights Switch 86 Head Light Dip Switch 87 Front Working Lights Switch 88 Rear Working Lights Switch 89 Interior Light Switch 90 Interior Light Switch 91 Beacon Switch 92 Heater Switch 93 Air Conditioning Switch 94 Air Conditioning Pressure Switch 95 Air Conditioning Pressure Switch 105 Electric Rear Window Switch * 106 Brake Fluid Low Level Warning Switch Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings. ..... continued

9803/3270

Issue 2*

Section C 18 - 3

Electrics Circuit Diagrams and Component Lists

Section C 18 - 3

Basic Machine Refer to pages C/18-1 and C18-4. Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 120 Road Lights Relay 121 Italian Worklight Relay 122 Heater Relay 132 Front Working lights Relay 133 Rear Working lights Relay

* Cable Colour Code B Black N Brown S Slate G Green O Orange U Blue K Pink P Purple W White LG Light Green R Red Y Yellow

Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 154 Main Beam Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 157 Master Warning Lights 158 Side Lights Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 161 Rear Fog Light Indicator Light 162 Rear Fog Light 163 LH Main Beam Light 164 RH Main Beam Light 165 LH Dip Beam Light 166 RH Dip Beam Light 167 LH Number Plate Light 168 LH Tail Light 169 LH Side Light 170 RH Number Plate Light 171 RH Tail Light 172 RH Side Light 173 Front Working Lights 174 Rear Working Lights 175 Brake Fluid Low Level Warning Light

9803/3270

Issue 3*

Section C

Electrics

18 - 4

Section C


18 - 4

Basic Machine FROM PAGE C/18-1

35

34

162

164 165 163

27

29

168

173

171

174

42

89

33

31

30

166

167 169 170 172 37 36

39

41

90

32

95

26

40 84

25 78 79 157

158 156

94

86

86

87

80

160 154 159 161 153

83 82

88 85

121

132

81

93

91

133

92

120

119

A274000 (CAD 852/302142 sheet 2 iss 5)

9803/3270

Issue 3

Electrics

Section C 18 - 5

Section C


18 - 5

Powershift (PS700) Transmission & Steer Circuit - AWS Machines Only

63

16

61

5

3

12 68

43 44 8

1

140

9

102

16

136 141

134

112 46

114

47

48

45

117

102 4

135

115

53

101

116 124

127

67 100

113

110

114 64 96

176

175

49

97

50

51

177 178 52

62

98

2

111 119

9803/3270

99

A274010 (CAD 852/30214-2/6 iss 3

Issue 3

Section C


18 - 6 * Powershift

Section C 18 - 6

Transmission (PS700) & Steer Circuit - AWS Machines Only

Refer to page C/18-5 Note: Except for the transmission and steer circuits (shown opposite), the AWS electrical circuit is the same as shown on Page C/18-1 to C/18-4. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 12 Hydraulic Speed Control Solenoid 16 Diode 43 Mainshaft solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Crab/4 Wheel Steer Solenoid 50 4 Wheel Steer Solenoid 51 Crab Solenoid 52 2 Wheel Steer Solenoid 53 Steer Mode Printed Circuit Board

Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 96 4 Wheel Drive Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch 101 4 WS/Crab Selector (part of PCB - item 53) 102 2 WS/4 WS Selector (part of PCB - item 53)

9803/3270

Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 123 Neutral Relay 124 Auto 2 Wheel Drive Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 134 Auto Hydraulic Speed Control Relay 135 Driveshaft interlock Relay 136 Driveshaft Relay Lights 140 LH Brake Light 141 RH Brake Light 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination

Issue 3*

Section C 18 - 7


Section C 18 - 7

* Powershift

Transmission (PS700) - 2WS Machines Only and Steer Circuit for 3CX 4x4x4 Machines Refer to page C/18-8 Note: Except for the transmission and steer circuits (shown opposite), the 2WS and the 3CX 4x4x4 electrical circuit is the same as shown on Page C/18-1 to C/18-4. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 12 Hydraulic Speed Control Solenoid 16 Diode 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 50 4 Wheel Steer Solenoid 52 2 Wheel Steer Solenoid 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch

9803/3270

Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 125 Driveshaft Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 129 4 Wheel Steer Relay 130 2 Wheel Steer Relay * 131 Steer Relay 1 * 132 Steer Relay 2 134 Auto Hydraulic Speed Control Relay * 135 Driveshaft Interlock Relay 136 Drive Relay (Layshaft & Mainshaft) Lights 140 LH Brake Light 141 RH Brake Light 147 Park Brake Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination

Issue 4*

Section C 18 - 8

Electrics

Section C


Powershift Transmission (PS700) - 2WS Machines

18 - 8

Steer Circuit for 3CX 4x4x4 Machines

132

A274021 (CAD 852/30214-6/6 issue 3)

9803/3270

Issue 4

Section C 18 - 9

Electrics

Electrics



Section C 18 - 9

* 3CXE (214E Series 3) Machines Only

A274310

9803/3270

Issue 2*

Section C 18 - 10 * 3CXE

Electrics

Section C


18 - 10

(214E Series 3) Machines Only - Component List

Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 15 Rear Horn 16 Diode 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 35 Horn (Front) 37 Strobe Light Socket 54 Warning Buzzer Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 70 Rear Horn 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 83 Horn Push (Front) 87 Front Working Lights Switch 88 Rear Working Lights Switch 96 4 Wheel Drive Switch

9803/3270

Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 118 Rear Horn Relay 119 Ignition Relay ‘2’ 132 Front Working lights Relay 133 Rear Working lights Relay Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 153 Hazard Warning Indicator Light 155 Gauge Illumination 156 Turn Signal Indicator Light 159 Rear Work Lights Indicator Light 160 Front Work Lights Indicator Light 173 Front Working Lights 174 Rear Working Lights Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

Issue 2*

Section C


18 - 11 * 3CXE

Section C 18 - 11

(214E Series 3) Machines Only

FROM PAGE C/18 - 9

173

174

35 26

25

87 156

153

159 160

88

83

132

133

119

A274320 (CAD 852/30213) A274320

9803/3270

Issue 2*

Section C 18 - 12

Electrics

Electrics

Section C



18 - 12

214e Series 4 Machines Only

19 35 5

3

7 8

60 6

140

9

1

143

20

145

40 37

10

13

58

31

142

144

33

61 141

32

34

113 41

4

97 72

116

114

17 80

82 96

115 110

92

25

83

22

23

21

62 112

64 71

111 2

A313490 (CAD 852/30219

9803/3270

Issue 2

Electrics

Section C 18 - 13

Section C


18 - 13

214e Series 4 Machines Only Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 13 Hydraulic Auxiliary Connector 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 28 Clock 29 Face Level Fan 31 Rear Washer Motor 32 Rear Wiper Motor 33 Washer Motor 34 Front Wiper Motor 35 Horn (Front) 37 Beacon/Strobe Light Socket 39 Radio 40 Heater Motor 41 Heater Resistor 58 Hammer Solenoid 59 Psion Electrical Connector 60 Cab Auxiliary Power Socket

Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 119 Ignition Relay ‘2’ 132 Front Working lights Relay 133 Rear Working lights Relay Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 173 Front Working Lights 174 Rear Working Lights Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 78 Face Level Fan Switch 80 Rear Washer/Wiper Switch 82 Front Washer/Wiper Switch 83 Horn Push (Front) 87 Front Working Lights Switch 88 Rear Working Lights Switch 92 Heater Switch 9803/3270

Issue 2

Section C 18 - 14

Electrics

Electrics



Section C 18 - 14

214e Series 4 Machines Only

74

76

59 73

75

77

174

173 39 26

60 29

54

87 78 88

24

147 149 151 146 148 150 152

28

18 132

133

119

A313410

9803/3270

Issue 2

9803/3270 9 8 7

1

FUSE P2

FUSE P1

FUSE P4

FUSE P1 40A FUSE P2 50A FUSE P3 50A FUSE P4 60A 2

2 1 3 4 5 6 4

6

126

2

8 5 6 7 6 1 3 8

111 1 65 1 3

2

8

67 1 8 6 1 3 8

83 1

10

7

8 5

18 17

4

71 1

1 3

23 1

9

9

9

9

HOURMETER

TACHOMETER

9

408

TACHOMETER

FUEL SENDER

20 1

M

34 1

ILLUMINATION

22 1

FUEL GAUGE

19

-

17 1 WATER TEMP SENDER


9

2

FLASHER UNIT

RH REAR INDICATOR

RH FRONT INDICATOR

LH REAR INDICATOR

LH FRONT INDICATOR


U

144 1 409

33 1

WATER TEMP GAUGE

806

805

HAZARD SWITCH

FRONT HORN

FRONT WIPER

Electrics

+

6

401

806

814

841

FRONT WASHER PUMP

HAMMER

WHEEL ALIGN SWITCH

RAER PROXIMITY SWITCH

FACE LEVEL FAN

INTERIOR LIGHT

REAR WIPER

REAR WASHER PUMP

HEATER RELAY

HEATER

E.S.O.S.

RH BRAKE LIGHT

LH BRAKE LIGHT

4WD SWITCH

4WD SOLENOID

P/BRAKE RELAY

P/BRAKE WARNING RELAY

REVERSE ALARM

REVERSE SOLENOID

Electrics

-

2 C2

31

72 1 +

82 7 1 U

2

49

5

3

49a

1

802

66 1

FLASHER RELAY

840

870

142 1

804

8

INDICATOR SWITCH

195

805

78 1 HAMMER FOOT SWITCH

7

FRONT HORN SWITCH

2

839

864

SUPER BRIGHT LED

3

HAMMER ISOL. SWITCH

977

862

M

FRONT WASH/ WIPE SWITCH

7

REAR PROXIMITY SWITCH

2

820

863

58 1

FUSE C4

5

31 1

300

4

35 1 143 1

104

2

HAZARD SWITCH

92 1 80

303

800B

61 1

FUSE A3

64 1 3 5

29 1

803

1

32 1

110

1 8

HEATER FAN MOTOR

40 1

FUSE B2

115 1 8

HEATER RESISTOR

116

110

6 8 7

101

10

FUSE A8

816

140 1

FUSE A1

7 7 10

REAR WASH/ WIPE SWITCH

6

800

4

41 1

FUSE C5

9

933

61 1 M

103

3

105

2 9

10 1

FUSE B5

62 1 3

117

HEATER SWITCH

114 141 1

102

4 6

853

7 1 8 1

FUSE C8

2

REVERSE RELAY

FORWARD SOLENOID

214Se Machines & 214e From Serial No.

FUSE A2

8 9

PARKBRAKE SWITCH

9 1

4 WB RELAY

1 7

877

113

REVERSE RELAY

811

6 1

BRAKE LIGHTS SWITCH

5 10

63 1

PARKBRAKE RELAY

815

808

4

R

3

N

812

60 1

FUSE B6

401

112 2

810

110 1 F

FORWARD RELAY

DUMP SWITCH (LOADER)

DUMP SWITCH (GEAR)

IGNITION RELAY 1

NEUTRAL START RELAY

STARTER SOLENOID

STARTER MOTOR

BATTERY

THERMOSTART

18 - 14A

FOR / REV SWITCH

912

6 5

IGNITION RELAY 1

8

809

FORWARD RELAY

4 1

107

FUSE A5

842

BATTERY

1

200

002

2

934

5

TRANS DUMP RELAY

NEUTRAL START RELAY

003

5 1

FUSE C9

004

FUSE C7

3 1

200C

200B

IGNITION SWITCH

010

Section C Section C 18 - 14A

4

145 1

M 412

407

M 401

7

25 1

21 24 1 1

828

2

106

830

828

829

007

001 011

FUSE P3 BATTERY FEED

200D/200M

200G

200E/200R

A347341 CAD 331/17034 sheet iss2

Issue 2

Section C 18 - 14B

Electrics

Section C


18 - 14B

* 214Se Machines & 214e From Serial No. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 6 Forward Solenoid 7 Reverse Solenoid 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 10 Fuel Pump Solenoid 13 Hydraulic Auxiliary Connector 17 Indicator Flasher Unit 18 Side Instrument Console 19 Coolant Temperature Sender 20 Fuel Gauge Sender 21 Tachometer 22 Coolant Temperature Gauge 23 Fuel Gauge 24 Hourmeter 25 Front Instrument Console 26 Alternator 29 Face Level Fan 31 Rear Washer Motor 32 Rear Wiper Motor 33 Front Washer Motor 34 Front Wiper Motor 35 Horn (Front) 37 Beacon/Strobe Light Socket 39 Radio 40 Heater Motor 41 Heater Resistor 58 Hammer Solenoid 60 Cab Auxiliary Power Socket 61 Interior Light/Switch 62 Buzzer Switches 60 Transmission Dump Switch (Gear) 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Rear Steer Proximity Switch 66 Steer Alignment Switch 67 Hammer Isolation Switch 71 Hazard Warning Switch 72 Direction Indicator Switch 73 Engine Coolant Temperature Switch 74 Transmission Oil Temperature Switch 75 Engine Oil Pressure Switch 76 Transmission Oil Pressure Switch 77 Air Filter Restriction Switch 78 Face Level Fan Switch 80 Rear Washer/Wiper Switch 82 Front Washer/Wiper Switch 83 Horn Push (Front) 9803/3270

87 88 92 93 94 95

Front Working Lights Switch Rear Working Lights Switch Heater Switch Dip/main Light Switch Road lights Switch Hammer Foot Switch

Relays 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 4 Wheel Drive Relay 119 Ignition Relay ‘2’ 132 Front Working lights Relay 133 Rear Working lights Relay 134 Road lights Relay Lights 140 LH Brake Light 141 RH Brake Light 142 LH Front Indicator 143 LH Rear Indicator 144 RH Front Indicator 145 RH Rear Indicator 146 Alternator Warning Indicator Light 147 Park Brake Indicator Light 148 Water Temperature Indicator Light 149 Transmission Temperature Indicator Light 150 Engine Oil Pressure Indicator Light 151 Transmission Oil Pressure Indicator Light 152 Air Filter Blocked Indicator Light 173 Front Working Lights 174 Rear Working Lights 175 Front Dip and Main Lights 176 LH Tail and Side lights 177 RH Tail and Side lights Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings. Option - Smooth Ride System (SRS) 1 Selector Switch 2 Accumulator Switch

Issue 2*

9803/3270 BATTERY FEED 2

007 8 4

119

6 6 8 2

6

7

93

2

8

5

8

134 4

6

1

94

828 2

828

88

6

5

3 7

2 8

3

1801

830

ACCUMULATOR SOLENOIDS

FUSE C10

837

834

W

'SRS' SWITCH

FUSE A10

829

17

FUSE A9

836

833

FUSE C2

WATER TEMP SWITCH

LIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

DIPPER SOCKET

LH SIDE LIGHT

LH TAIL LIGHT

RH MAIN BEAM

LH MAIN BEAM

LH DIP BEAM

RH DIP BEAM

STROBE LIGHT SKT

LIGHTS RELAY

REAR WORKING LIGHTS

FRONT WORKING LIGHTS

IGNITION RELAY 2

POWER SOCKET

RADIO SOCKET

ALTERNATOR

AIR FILTER VAC. SWITCH

TRANS OIL PRESS SWITCH

ENGINE OIL PRESS SWITCH

TRANS OIL TEMP SWITCH

Electrics Electrics

Circuit Diagrams and Component Lists Circuit Diagrams and Component Lists

7 3

2

95

600

4

2

832

401

176

829

5 3

DIP/MAIN SWITCH

175

101

5 1

ROAD LIGHTS SWITCH

2

861

407

311

132

6

127

5

861

76

FUSE C3

011 312

5 4

ROAD LIGHTS RELAY

106 3

R/W/L SWITCH

6

894

4

855

855

39

FUSE B10

18

173

FUSE B7

117

62

011

146 147 148 149 150 151 152 116

411

309

SIDE CONSOLE INSTRUMENTS

011

10

F/W/L SWITCH

11

402

77

FUSE B9

310

114

26

IGNITION RELAY 2

FUSE B4

412

304

407

BUZZER

9

405

75

FUSE B8

829 403

74

AIR FILTER

12

TRANS OIL PRES

73

ENGINE OIL PRES

18

404

406

18 - 14C

FUSE C6

106

7

FUSE B1

3

TRANS OIL TEMP

16

WATER TEMP

HAND BRAKE

ALTERNATOR

Section C Section C 18 - 14C

214Se Machines Only

OPTIONS

177

174

60 37 61

87 7

8

133 7

2

830

5

8

'SRS' SMOOTH RIDE SYSTEM

200D/200M

200G

200E/200R

Issue 3

Section C

Electrics

Section C


18 - 15

18 - 15

Autoshift Transmission - 2WS Machines Only

1 2 5

4 3 70 71

90

50 72 6 73

7

8 51 9 52 53 54

10 11 12

16

13 55

14 77

15

180D

74

17

18

56

19

75 57 76

A299420 (CAD 852/30214 sheet 5 iss 5

9803/3270

Issue 2

Section C 18 - 16


Section C 18 - 16

Autoshift Transmission - 2WS Machines Only Refer to page C/18-15 Except for the circuits shown opposite the 2WS Autoshift electrical circuit is the same as shown on pages C/18-1 to C/18-4. Main Components 1 Thermostart 2 Battery 3 Starter Switch 4 Starter Solenoid 5 Starter Motor 6 Reverse Alarm 7 Speed Sensor 8 Autoshift Electronic Control Unit (ECU) 9 Forward Low Solenoid 10 Forward High Solenoid 11 Mainshaft Solenoid 12 Layshaft Solenoid 13 Reverse Low Solenoid 14 Reverse High Solenoid 15 Autoshift Gear Selector 16 Autoshift Gear Selector 17 Warning Buzzer 18 Psion Tester Connection 19 Hydraulic Speed Control Solenoid Switches 50 Park Brake Switch 51 Forward/Reverse Switch 52 Transmission Dump Switch 53 Autoshift Kickdown Switch 54 Autoshift Throttle Switch 55 Brake Mode Selector 56 Hydraulic Speed Control Switch 57 Hydraulic Speed Control Switch Relays 70 Neutral Start Relay 71 Parking Brake Relay 72 Ignition 1 Relay 73 Reverse Alarm Relay 74 Ignition 2 Relay 75 Hydraulic Speed Control Relay 76 Auto Hydraulic Speed Control Relay * 77 2 Wheel Brake Relay Lights 90 Parking Brake Indicator Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

9803/3270

Issue 2*

Section C

Electrics

Section C


18 - 17

18 - 17

Autoshift Transmission - AWS Machines Only

1 2 4

5

3 70 71

90

50 72 6

73

7

8 51 9 52 53

10

54 11 12

16

13 14 55

15

17 74

18

75

56

76

19 57

A316310

9803/3270

Issue 1

Section C 18 - 18


Section C 18 - 18

Autoshift Transmission - AWS Machines Only Refer to page C/18-17 Except for the circuits shown opposite the AWS Autoshift electrical circuit is the same as shown on pages C/18-1 to C/18-4. Main Components 1 Thermostart 2 Battery 3 Starter Switch 4 Starter Solenoid 5 Starter Motor 6 Reverse Alarm 7 Speed Sensor 8 Autoshift Electronic Control Unit (ECU) 9 Forward Low Solenoid 10 Forward High Solenoid 11 Mainshaft Solenoid 12 Layshaft Solenoid 13 Reverse Low Solenoid 14 Reverse High Solenoid 15 4 Wheel Drive Solenoid 16 Autoshift Gear Selector 17 Warning Buzzer 18 Psion Tester Connection 19 Hydraulic Speed Control Solenoid Switches 50 Park Brake Switch 51 Forward/Reverse Switch 52 Transmission Dump Switch 53 Autoshift Kickdown Switch 54 Autoshift Throttle Switch 55 4 Wheel Drive Switch 56 Hydraulic Speed Control Switch 57 Hydraulic Speed Control Switch Relays 70 Neutral Start Relay 71 Parking Brake Relay 72 Ignition 1 Relay 73 Reverse Alarm Relay 74 Ignition 2 Relay 75 Hydraulic Speed Control Relay 76 Auto Hydraulic Speed Control Relay Lights 90 Parking Brake Indicator Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings.

9803/3270

Issue 1

Section C


18 - 19 * Powershift

Section C 18 - 19

Transmission (PS750) & Steer Circuit - AWS Machines Only

Refer to page C/18-20 Note: Except for the transmission and steer circuits (shown opposite), the AWS electrical circuit is the same as shown on Page C/18-1 to C/18-4. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 9 2/4 Wheel Drive Solenoid 12 Hydraulic Speed Control Solenoid 16 Diode 43 Mainshaft solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Crab/4 Wheel Steer Solenoid 50 4 Wheel Steer Solenoid 51 Crab Solenoid 52 2 Wheel Steer Solenoid 53 Steer Mode Printed Circuit Board

Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 96 4 Wheel Drive Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch 101 4 WS/Crab Selector (part of PCB - item 53) 102 2 WS/4 WS Selector (part of PCB - item 53)

9803/3270

Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 124 Auto 2 Wheel Drive Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 134 Auto Hydraulic Speed Control Relay 135 Driveshaft Interlock Relay 136 Driveshaft Relay Lights 140 LH Brake Light 141 RH Brake Light 142 Parking Brake Indicator Light 175 4 Wheel Steer Indicator Light 176 Crab Steer Indicator Light 177 2 Wheel Steer Indicator Light 178 Front Instrument Console Illumination

Issue 2

Electrics

Section C 18 - 20

Section C


18 - 20

Powershift (PS750) Transmission & Steer Circuit - AWS Machines Only

63

16

12 68

43 44

5

3

61

8

9

1

140 112

53

141

48

136 46

45

102 47

117

134

116

4

135 115

124

126

101

127 110

142

113

114

67 100

16 16 64 97

96

50

62

176

175

49

51

177 178 52

16

98

99

2 111

9803/3270

119

A325210 (CAD 852/30214 sheet 3 iss 5

Issue 1

Section C

Section C

Electrics

18 - 21


18 - 21

Steer Circuit for 3CX 4x4x4 Machines

Powershift Transmission (PS750) - 2WS Machines

12

63 3

5

61

49

43 44

16

112

140

1

68

141

125

8

65

117 46

45

48

132

131

47 134

4

135

115

116 63 126

124

110

114

113

147

67

127

130 16

50

100

178

16 62

52 64 16

177

129 97

99

98

2 111

119

A325220 (CAD 852/30214 sheet 4 issue 5)

9803/3270

Issue 1

Section C 18 - 22


Section C 18 - 22

Powershift Transmission (PS750) - 2WS Machines Only and Steer Circuit for 3CX 4x4x4 Machines Refer to page C/18-21 Note: Except for the transmission and steer circuits (shown opposite), the 2WS and the 3CX 4x4x4 electrical circuit is the same as shown on Page C/18-1 to C/18-4. It should be noted that some of the options shown may not be fitted on all machine models. Main Components 1 Battery 2 Starter Switch 3 Thermostart 4 Starter Solenoid 5 Starter Motor 8 Reverse Alarm 12 Hydraulic Speed Control Solenoid 16 Diode 43 Mainshaft Solenoid 44 Layshaft Solenoid 45 Forward Low Solenoid 46 Forward High Solenoid 47 Reverse High Solenoid 48 Reverse Low Solenoid 49 Drive/Brake Solenoid 50 4 Wheel Steer Solenoid 52 2 Wheel Steer Solenoid

Switches 61 Transmission Dump Switch (Loader) 62 Forward/Reverse Switch 63 Park Brake Switch 64 Brake Light Switch 65 Brake/Drive Select Switch 67 Hydraulic Speed Control Switch 68 Hydraulic Speed Control Switch 97 Powershift Column Switch 98 Front Proximity Switch 99 Rear Proximity Switch 100 Steer Mode Select Switch

9803/3270

Relay 110 Neutral Start Relay 111 Ignition Relay ‘1’ 112 Transmission Dump Relay 113 Forward Relay 114 Reverse Relay 115 Park Brake Relay 116 4 Wheel Brake Relay 117 Hydraulic Speed Control Relay 119 Ignition Relay ‘2’ 124 Auto 2 Wheel Drive Relay 125 Driveshaft Relay 126 Forward High/Low Relay 127 Reverse High/Low Relay 129 4 Wheel Steer Relay 130 2 Wheel Steer Relay 131 2 Wheel Steer Solenoid Relay 132 4 Wheel Steer Solenoid Relay 134 Auto Hydraulic Speed Control Relay 135 Driveshaft Interlock Relay Lights 140 LH Brake Light 141 RH Brake Light 147 Park Brake Indicator Light 177 2 Wheel Steer Indicator Light 178 4 Wheel steer Indicator Light

Issue 1

Section C

Electrics

Section C


18 - 23

18 - 23

Auxiliary Electrical Options

6 3 2 5

2

2

3

4

1

4

1

3

1

2

1

Fuse B4

A308350 CAD 852/30214

Fuse A1

Fuse A1 Fuse A1

Hand Held Tools (Gear Pump) 1 2 3

Switch Indicator Lamp Solenoid

9803/3270

Dedicated Quick Hitch

Pole Planter

Smooth Ride System (SRS)

1 2 3 4 5 6

1 2 3

1 Selector Switch/LED 2 Accumulator Solenoids

Hydraulic Enable Switch Indicator Lamp Warning Buzzer Operator Switches Relay Solenoid

Selector Switch Grab Solenoid Rotation Solenoid

Issue 1

Section C

Electrics

Section C


18 - 24

18 - 24

(M) 600

Auxiliary Electrical Options (continued)

4 4

(M) 870

3

(P) 600

898 (P)

3

2

801

(M) 899

2

1

101 (P) 10A

(M) 101

1

Fuse A1

Fuse A1

Hammer

Hand Held Tools (Variable Flow Pump)

1 2 3 4

1 2 3 4

Micro Switch Relay Panel Switch Hammer Solenoid

9803/3270

Switch Indicator Lamp Solenoid (normally open) Solenoid

Issue 1

Electrics

Section C 18 - 24A


Section C 18 - 24A


Hammer and Jaw Changeover Circuit 1 Foot Pedal Switch 2 Hammer Relay 3 Excavator Lever Switch 4 Jaw Relay 5 Panel Switch 6 Hammer Solenoid 7/8 Jaw Solenoid

9803/3270

Issue 1

Section C

Electrics

Section C


18 - 25

18 - 25


5 5

7 920

6

8

870

4

3 1830

4

600

898

3

101

2 899

2

10A

101

101

1

1

Powershift (PS750) 2/4WD Powered On 2WD (Germany) 1 2 3 4 5

Brake Light Switch Brake Mode Switch Auto 2WD Relay 4 Wheel Brake Relay 4WD/4WB Relay

9803/3270

Fuse A1

* Power Sideshift with Hammer Circuit 1 2 3 4 5 6 7 8

Micro Switch Hammer Relay Hammer Switch Hydraclamp Switch Hammer Solenoid Hydraclamp Solenoid Power Sideshift Solenoid Buzzer Issue 2*

Section C 18 - 26

Electrics

Section C


18 - 26

Servo Command Up To Serial No. 495454 The circuit shown refers to the Servo option only, for the remainder of the circuit see the appropriate additional circuit. Main Components 1 Starter Switch 2 Return To Dig Switch 3 Servo Enable Switch 4 Sweeper Blower Switch 5 Shovel Limit Switch 6 Forward Seat Proximity Switch 7 Rearward Seat Proximity Switch 8 Mode Changeover Switch 9 Stabiliser Switch 10 Float Electro Magnetic Latch Coil 11 Return To Dig Electro Magnetic Latch Coil 12 Hydraulic Speed Contol Switch 13 Transmission Dump Switch 14 Auxiliary Switch 15 Rear Horn 16 Quick Hitch Switch 17 Left Hand Amplifier 18 Left Hand Proportional Rocker Switch 19 Right Hand Amplifier 20 Right Hand Proportional Rocker Switch 21/22 Manifold Arms/Boom Changeover Solenoid 23/24 Manifold Shovel/Bucket Changeover Solenoid 25/26 Loader Solenoid 27/28 Auxiliary Solenoid 29/30 Excavator Left Hand Stabiliser Solenoid 31/32 Excavator Right Hand Stabiliser Solenoid 33 Manifold Left Hand Pilot Pressure Valve 34 Manifold Left/Right Hand Pilot Pressure Valve 35/36 Auxiliary Option Solenoid 37 Alarm

R20 R21 R22 R23

Stabiliser Lower Changeover Stabilser Raise Changeover Stabiliser Lower Mode Changeover Stabiliser Raise Mode Changeover

On the illustration: B = Bottom T = Top H = Head R = Rod

Relays R1 Ignition R2 Front Seat R3 Front Mode Changeover R4 Rear Seat R5 Rear Mode Changeover R6 Spare R7 Dump Interlink (autoshift only) R8 Front Auxiliary Supply R9 Hammer Interlink R10 Stabiliser Isolator R11 Spare R12 Sweeper/Clam Changeover R13 Pilot Valve Changeover R14 Auxiliary/Clam 2 Changeover R15 Auxiliary/Clam 1 Changeover R16 Stabiliser/Clam 2 Changeover R17 Stabiliser/Clam 1 Changeover R18 Stabiliser/Auxiliary 1 Changeover R19 Stabiliser/Auxiliary 2 Changeover

9803/3270

Issue 1

Electrics

Section C 18 - 27

Section C


18 - 27

Servo Command Pilot Circuit Up To Serial No. 495454

+12V 1816

1

1808

200V

IGN SW

1813

PUMP DUMP

1806

1811

D6

RTD

D1

1805

11

D7

12 13 14 15

1824

R3

R2

R4

931

1V

1823

1825

1822

1827

0V

0.5k 10V

9V

D9

18

D8

16

D5

1833

D2

7

6

1850

D11 FUSE 5A

R5

4k

0.5k

1812 1810

4

1

PROPORTIONAL SWITCH. LH STAB, AUX.OPT.

1821

5

19

RH AMPLIFIER 3

1807

2

4

1

D10

HAMMER SOLENOID FEED

PROPORTIONAL SWITCH. CLAM, AUX, RH STAB.

1842

1807

1841

1843

FROM TACHO ILLUMINATION

921

934

AUX FEED

FUSE 1A

1814

2

1826

STAB

10 FLOAT

REAR HORN

RTD

2

875

S3

AUX

7

934

6

R

F

4 7

TRANS DUMP

L3

17

LH AMPLIFIER 3

EXISTING +VE FEED TO HORN

FROM HSC RELAY

1805

2

112

3

3 ENABLE SWITCH

1839

SERVO S1

8

5

1809

L1

2

1840

8

2

1846

7

8 9

SWEEPER BLOWER SWITCH

L2

R7 TO AUTO ECU

603

6

7

5

FUSE 5A

1804

3

8

830

6

S2

5

131

012

MODE

1808

7

6

1851

929

R1

FROM TRANS DUMP RELAY

930

844

QUICK HITCH SWITCHES

AUTO DUMP RELAY

SERVO BUZZER

FUSE 15A

FUSE 3A

FUSE 10A

101AB

D4

107

D3

12V +VE FEED

870

870

R10

R9

R13

R12

R14

4k

0.5k

1844

R8

R15

R16

R18

R17

0V

R19

1V

0.5k 9V

10V

20 1845

1838 1834

1832

1849

1847 1807 947

1848

R23

21

22

ARMS/BOOM CHANGEOVER VALVE

23

24

SHOVEL/BUCKET CHANGEOVER VALVE

25 H

T

26B

LOADER VALVE

R

27

R

28

AUX VALVE

H

29 T

H

30

B

R

31 T

EXCAVATOR VALVE

H

32 B

R

33 LH PILOT

FUSE 5A

AUX OPTION

1802

R.STAB

1803

R.STAB

955

L.STAB

956

953

L.STAB

954

AUX EXT DIP

957

AUX EXT DIP

958

CLAM

959

CLAM

960

1836

6

34

5

LH/RH PILOT

AUX OPTION

35

1831

R22

1828

R21

FUSE 5A

1837

1829

R20

36 AUX VALVE

GROUND

A352750 (CAD 852/30214 sheet 8 iss 1

9803/3270

Issue 3

9803/3270 200

001 8 2

6 8 10

002

16 18 1 3

200

30 31

13 32

830 2

35 36 37 38 39 40 41

BUZZER

45 45 45

33

830 806

45 46

43

47 48 49 50

FUEL SENDER

RADIO

WARNING CLUSTER

INSTRUMENT PANEL

AIR FILTER VAC. SW

TRANS OIL PRESS SWITCH

ENGINE OIL PRESS SWITCH

TRANS OIL TEMP SWITCH

WATER TEMP SWITCH

HOURMETER

TACHOMETER

CLOCK

WATER TEMP SENDER

Electrics

53 54 55 56 57 RH SPEAKER

412

51

304A

402

405

403

404

406

LH SPEAKER

REAR FOG

FRONT W/L

REAR W/L

MAIN BEAM

411

HAZARD WARNING

SIDE LIGHTS

TURN SIGNAL

LIGHTS

112

WARNING

MASTER

ILLUMINATION

AIR FILTER

TRANS OIL PRES

ENGINE OIL PRES

TRANS OIL TEMP

WATER TEMP

HAND BRAKE

ALTERNATOR

3

DIRECT EARTH

7

HOURMETER

0

617

26

TACHOMETER

CLOCK

408

25

4

-

FUEL GAUGE

409

19 - 1

804

17 4

29 U

18 -

4 WATER TEMP GAUGE

FLASHER UNIT

28

304

U

FLASHER UNIT

RH FRONT INDICATOR ROOF-USA RH REAR INDICATOR ROOF-USA

RH REAR INDICATOR

RH FRONT INDICATOR

LH FRONT INDICATOR ROOF-USA

LH REAR INDICATOR ROOF-USA

LH FRONT INDICATOR

LH REAR INDICATOR

HAZARD SWITCH

REAR HORN

IGNITION RELAY 2

E.S.O.S.

COLD START ADVANCE

IGNITION RELAY 1

ALTERNATOR

NEUTRAL START RELAY

STARTER SOLENOID

STARTER MOTOR

BATTERY

THERMOSTART

27

FUSE C4

17 C2

31

2

+

+

9

FUSE B1

5 49

49a

24

106

8

300

15

23

802

B/O

22

104

805

21

806

806

20

FUSE C2

4

B/N

871

19

FUSE A3

804

111 INDICATOR SWITCH

921

6

803

FUSE B3

118

113

HAZARD SWITCH

007

12

PRIMARY FUSE 1

6

14

IGNITION RELAY 2

105

5

200

4 2

133

4

WAXSTAT

BATTERY ISOLATOR

10

FUSE A2

810 TO GEARBOX CONTROL FEED

6

107

FUSE A5

200

11

IGNITION RELAY 1

002

8

W

200

2

FROM NEUTRAL SELECT

842

8

133

004

BATTERY

3

FUSE C7

KEY SWITCH

003

NEUTRAL START RELAY

FUSE C5 1

PRIMARY FUSE 3

PRIMARY FUSE 4

200

010

Section C Section C

Circuit Diagrams and Component Lists 19 - 1

Basic Machine From Serial Number 495455 To 499999 And From 920000

859 EARTH

601

60

860

59

602

58

407 805 407

44 401

FRONT CONSOLE INSTRUMENTS

42 52

INSTRUMENTS

34 SIDE CONSOLE 835

855

861

837

830

200

007

002

133

001

A370020

Issue 2

Section C 19 - 2


Section C 19 - 2

Basic Machine From Serial Number 495455 To 499999 And From 920000 Refer to pages C/19-1 and C19-4. The basic circuit shows a standard machine. The remaining pages in section C/19 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown. Main Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Thermostart Battery Isolator Battery Starter Switch Neutral Start Relay Starter Solenoid Starter Motor Alternator From Neutral Selector Cold Start Advance Cold advance switch Engine Shut Off Switch (ESOS) To Gearbox Control Feed Ignition Relay ‘1’ Ignition Relay ‘2’ Hazard Warning Switch Indicator Flasher Unit Direction Indicator Switch LH Rear Indicator LH Front Indicator LH Rear Roof Indicator (N. Am) LH Front Roof Indicator (N. Am) RH Front Indicator RH Rear Indicator RH Front Roof Indicator (N. Am) RH Rear Roof Indicator (N. Am) Coolant Temperature Sender Fuel Gauge Sender Coolant Temperature Gauge Fuel Gauge Clock Tachometer Hourmeter Side Instrument Console Alternator Warning Indicator Light Park Brake Indicator Light Water Temperature Indicator Light Transmission Temperature Indicator Light Engine Oil Pressure Indicator Light Transmission Oil Pressure Indicator Light Air Filter Blocked Indicator Light Panel Illumination Warning Buzzer Front Instrument Console Master Warning Lights Turn Signal Indicator Side Lights Indicator Hazard Warning Indicator Main Beam Warning Indicator Light Rear Working Light Indicator

9803/3270

51 52 53 54 55 56 57 58 59 60 111 112 113

Front Working Light Indicator Rear Fog Light Indicator Engine Coolant Temperature Switch Transmission Oil Temperature Switch Engine Oil Pressure Switch Transmission Oil Pressure Switch Air Filter Restriction Switch Radio (if fitted) RH Speaker LH Speaker Rear Horn Switch Rear Horn Relay Rear Horn

Issue 3

Section C 19 - 3


Section C 19 - 3

* Basic Machine From Serial Number 495455 To 499999 And From 920000 (cont) 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110

Cigar Lighter Face Level Fan Face level Fan Switch Heated Seat Heated Seat Switch Rear Washer/Wiper Switch Rear Wiper Motor Rear Washer Motor Front Washer/Wiper Switch Front Washer Motor Front Wiper Intermittent Electronic Control Unit Front Wiper Motor Head Light Flasher Switch Horn (Front) Push Switch Horn (Front) Rear Fog Light Switch Rear Fog Light Removed For Territories - Italy, Germany Fitted For Territories - Italy, Germany Road Lights Relay Road Lights Switch Head Light Dip Switch LH Main Beam Light RH Main Beam Light LH Dip Beam Light RH Dip Beam Light LH Tail Light LH Side Light Socket (Dipper Light) Number Plate Light RH Tail Light RH Side Light Engine Running Relay Front Working Lights Relay Rear Working Lights Relay Front Working Lights Switch Rear Working Lights Switch Front Working Lights Rear Working Lights Interior Light Beacon Switch Beacon Heater Switch Heater Relay Heater Motor Heater Resistor Air Conditioning Switch Air Conditioning Pressure Switch Air Conditioning Pressure Switch Air Conditioning Compressor

9803/3270

Fuses A1 - A10 B1 - B10 C1 - C10 Refer to Technical Data pages at the beginning of Section C for further fuse details and ratings. Cable Colour Code B Black N Brown S Slate G Green O Orange U Blue K Pink P Purple W White LG Light Green R Red Y Yellow

Issue 2*

200

9803/3270

73 10

80 8 7

6

830

78

7

835

855 4

861 6

93 5 3 1 2

8 2

4

6

97

94 8

110

8

95

837 800

828

BEACON SWITCH

2 7

7 3

8

105 106 904

HEATER FAN MOTOR 935

B/P

B/Y

B/Y

B/U

B/U

B/G

835

1042 8

B

B

101 2

2

AIR-CONDITIONING

HEATER RELAY

HEATER

BEACON

INTERIOR LIGHT

REAR WORKING LIGHTS

FRONT WORKING LIGHTS

LIGHT SWITCH

RH SIDE LIGHT

RH TAIL LIGHT

No PLATE LIGHT

DIPPER SOCKET

LH SIDE LIGHT

LH TAIL LIGHT

RH DIP BEAM

LH DIP BEAM B B

RH MAIN BEAM

LH MAIN BEAM

LIGHTS RELAY

B

B

FOG LIGHT

FRONT HORN

Electrics


86

4

7

8

AIR-CON COMPRESSOR

903

HEATER RESISTOR

102

902

861

861

855

855

100

HEATER RELAY

7

894

830

FUSE C9

834

837

814

FOG LIGHT SWITCH

M

AIR-CON SWITCH

81

3

HEATER SWITCH

5 1

102

4 6

R/W/L SWITCH

FUSE A10

829

833

841

91

FUSE C7

ROAD LIGHTS SWITCH

4

FUSE C3

2

5

99

303

5

3

FUSE B8

3

117

6

98

309

74

6

FUSE B10

116

79

FUSE A9

82

89

310

2

87

F/W/L SWITCH

8

836

INTERMITTENT ECU

FUSE C10

76

DIP SWITCH

3

88

1133

8

FRONT WIPER

FRONT WASHER PUMP

REAR WIPER

REAR WASHER PUMP

HEATED SEAT

FACE LEVEL FAN

CIGAR LIGHTER

19 - 4

407

67

832

868

7

FUSE C1

71

TERRITORIAL OPTION ITALY, GERMAN ONLY

64 84 85

ENGINE RUNING RELAY

3

829

69 FRONT HORN SWITCH

M

984

840

83

FUSE C1

1

982

983

M

311

6 7

M

127

1133

66

FRONT W/W SWITCH

77

ROAD LIGHTS RELAY

2

839

68

H/LIGHT FLASH

5

864

862

M

110

65 863

407

FUSE B2

63 HEATED SEAT SWITCH

70 75

FUSE B9

133

62

FUSE B5

REAR WASH/ WIPE SWITCH

830

61

103

114

72

REMOVED FOR TERRITORIES ITALY, GERMAN ONLY

007

FUSE B4

Section C Section C 19 - 4

Basic Machine From Serial Number 495455

90 92 110

109

M

96 108

6 3

107 2

829

103

2

1853

001

PRIMARY FUSE 2

A370020

Issue 1

9803/3270 13 TO FUSE A5 TO FUSE A5 14 7

1

4

810

6

2

TO NEUTRAL START RELAY

1 2 2WS WRNG LIGHTS

3 11

12

4

13

2WS/4WS MODE SELECTOR

812

848

811

849

STEER MODE P.C.B.

PROXIMITY SWITCHES

FORWARD HIGH SOLENOID

FORWARD LOW SOLENOID

REVERSE HIGH SOLENOID

REVERSE LOW SOLENOID

REVERSE ALARM

TRANSMISSION EARTH

LAYSHAFT SOLENOID

MAINSHAFT SOLENOID

DUMP SWITCH (LOADER)

P/BRAKE SWITCH

Electrics

14

15 16 17

(FRONT CONSOLE)

825

9

2WS SOLENOID (SIDE CONSOLE)

5 4WS/CRAB MODE SELECTOR

4

CRAB WRNG LGHT

824

826

4WS RELAY

2WS RELAY

847

5

CRAB SOLENOID

6

8

4WS WRNG LGHT

20

4WS SOLENOID

8

845

6

7

CRAB/4WS SOLENOID

6

823

7

STR MODE SW

9

CRAB/4WS RELAY

10

CRAB RELAY

883

822

821

17 FORWARD H/L RELAY

3

FUSE B1

852

8

21

820

8

19

REAR PROX SW

2 819

3

10

858

12

856

5

6

FRONT PROX SW

5

3

7

4

852 9

3

1

5

2

2

2

REVERSE H/L RELAY

1

18

106

9

16

007

4 3

850

851

3

FUSE A4

TO NEUTRAL START RELAY

REVERSE ALARM

Powershift Transmission

109

1

1

6

15

107

810

8 11

883

4

POWER SHIFT GEAR SELECTOR

7

1

808

10 2

FOR / REV SWITCH

11

4

REVERSE RELAY

1

R

12 DRIVE RELAY

13

N

F

9

809

8

5

INTERLOCK RELAY

1 815

14

FORWARD RELAY

847

19 - 5

002

7

REVERSE SOLENOID

FORWARD/REVERSE RELAY

FORWARD SOLENOID

DUMP SWITCH (LOADER) DUMP SWITCH (GEARLEVER)

P/BRAKE SWITCH

Manual Transmission

107

4

TRANS DUMP RELAY

811

811

815

3

934

3 10

815

5

REVERSE RELAY

812

10

401

808

809

934

815

401

5 6

107

810

5

FOR / REV SWITCH

9 3 1

R

6

FORWARD RELAY 2

N

F

8

TRANS DUMP RELAY

10

934

815

401

8

107

107

810

Section C Section C


Transmission And Steering From Serial Number 495455 Steer Mode - 4CX and 3CX Super (4x4x4)

22 STEER MODE P.C.B.

10

10

7

18

A370040

Issue 1

Section C 19 - 6

Electrics

Section C


19 - 6

Transmission And Steering From Serial Number 495455 Manual Transmission

Steer Mode - 4CX and 3CX Super (4x4x4)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

To wire 401 on page C/19-1 Parking Brake Relay Parking Brake Switch Transmission Dump Relay Dump Switch on Loader Lever Dump switch on Gear lever Forward/Reverse Selector Lever Forward Relay To Neutral Start Relay on page C/19-1 Forward Solenoid Reverse Relay Reverse Solenoid To Fuse A5 on page C/19-1 Reverse Alarm

Powershift Transmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

To wire 401 on page C/19-1 Parking Brake Relay Parking Brake Switch Transmission Dump Relay Dump Switch on Loader Lever Gear Selector Switch Forward/Reverse Selector Lever Forward Relay To Neutral Start Relay on page C/19-1 Interlock Relay Drive Relay Reverse Relay Mainshaft Solenoid To Fuse A5 on page C/19-1 Layshaft Solenoid Reverse Alarm Reverse High/Low Relay Reverse Low Solenoid Reverse High Solenoid Forward High/Low Relay Forward Low Solenoid Forward High Solenoid

9803/3270

Front Proximity Switch Rear Proximity Switch Steer Mode Selector Switch Steer Mode Printed Circuit Board Crab/4WS Relay Crab Relay 2WS Relay 4WS Relay 4WS/Crab Selector (part of 4) 2WS/4WS Selector (part of 4) Crab/4WS Solenoid 4WS Solenoid 4WS Indicator Light Crab Solenoid Crab Indicator Light 2WS Solenoid 2WS Indicator Light Side Console 2WS Indicator Light Front Console

Issue 1

Section C 19 - 7

Electrics

Section C


19 - 7

Options From Serial Number 495455 2 Wheel Steer/Brake Mode

Auxiliary and Hydraclamp Hydraulics

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9

From 4th Gear Selector Auto 2 Wheel Drive Relay 4 Wheel Braking Relay Brake mode Selector Switch 4 Wheel Drive/4 Wheel Brake Solenoid Brake Light Switch LH Brake Light RH Brake Light

All Wheel Steer/Brake Mode 1 2 3 4 5 6 7 8

From 4th Gear Selector 4 Wheel Drive Selector Switch Brake Light Switch Auto 2 Wheel Drive Relay 4 Wheel Braking Relay 4 Wheel Drive Solenoid LH Brake Light RH Brake Light

9803/3270

Excavator Lever Push Button Selector Switch Auxiliary Selector Switch Floor Push Button Selector Switch Hydraclamp Selector Switch Jaw Relay Hammer Relay Jaw Solenoid Hammer Solenoid Hydraclamp Solenoid

Speedometer Option 1 2 3

Speed Sensor Speedometer Illumination

Issue 1

9803/3270 TH

1 2

2

6

1 5

3

101

7

4 2 4

830

3

107

8

304

8

FUSE A10

7 3

10

FUSE A5

1 974

8

SPEED SENSOR

6

920

SPEEDO

SPEED SENSOR

HYDRACLAMP SOLENOID

HAMMER SOLENOID

JAW SOLENOID

Auxiliary and Hydraclamp Hydraulics

FUSE C4

8

7

HAMMER RELAY

4

109

6

HYDRACLAMP SWITCH

2

870

874

7

899

898

3

AUX HYD SWITCH

3 5

872

873

JAW RELAY

RH BRAKE LIGHT

LH BRAKE LIGHT

4WB RELAY

4WD SOLENOID

AUTO 2WD RELAY

RH BRAKE LIGHT

LH BRAKE LIGHT

4 WB RELAY

19 - 8

FUSE A4

2

5

101

8

816

853

2WD/2WB 2WD/4WB 4WD/4WB SOLENOID

AUTO 2WD RELAY

All Wheel Steer/Brake Mode

FUSE A1

2

829

3

FUSE A7

8

ILLUMINATION

7

875

8 3

4WB RELAY

5

FUSE B6

1

877

5

FUSE A8

853

BR MODE SW

6

858

6

933

10

AUTO 2WD RELAY 2

126

4

BRAKE LIGHTS SWITCH

9

922

3

4WB RELAY

922

854

7

FROM 4 GEAR SELECTOR

6 816

877

1

107

4WD SWITCH

8 2

FUSE A5

6

3

830

2 AUTO 2WD RELAY

10

FUSE A7

FUSE A8

818

2 Wheel Steer/Brake Mode

ILLUNINATION

933

107

858

9

126

BRAKE LIGHTS SWITCH

TH

4

FUSE B6

FUSE A5

1 FROM 4 GEAR SELECTOR

Section C Electrics Section C


Options From Serial Number 495455 Speedometer

5 7 8 9

5

1

2 3

1

5

818

1830

A370080

Issue 1

Section C 19 - 9


Section C 19 - 9

Autoshift Transmission From Serial Number 495455

A378770

9803/3270

Issue 1

Section C 19 - 10


Section C 19 - 10

Autoshift Transmission From Serial Number 495455 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

From Ignition Relay 2, see item 15 page C/19-1 From Ignition Relay 1, see item 14 page C/19-1 From Parking Brake Relay, see item 36 page C/19-1 To Neutral Start Relay, see item 5 page C/19-1 Parking Brake Relay Parking Brake Switch Reverse Alarm Relay Reverse Alarm Speed Sensor Forward/Reverse Selector Switch Dump Switch Kickdown Switch Throttle Switch Autoshift Gear Selector Autoshift Electronic Controller All Wheel Steer Machines Only From Brake Switch, see item 3 page C/19-8 4 Wheel Drive Selector Switch 2 Wheel Steer machines Only Brake Mode Selector Switch From Brake Switch, see item 3 page C/19-8 2 Wheel Braking Relay Alarm To Hydraulic Speed Control Switch, see item 2 page C/19-12 Forward Low Solenoid Forward High Solenoid Mainshaft Solenoid Layshaft Solenoid Reverse Low Solenoid Reverse High Solenoid 4 Wheel Drive Solenoid Psion Diagnostic Connector

9803/3270

Issue 1

Section C

Electrics

Section C


19 - 11

19 - 11

2

ROADBREAKER SWITCH

3

9803/3270

929

QUICK-HITCH FEED SWITCH

858

114

FUSE A1

101

FUSE B4

BRAKE LIGHTS SWITCH 126

Powershift 4WD Auto 2WD In 4th Powered on 2WD German 1 Brake Light Switch 2 4 Wheel Brake Relay 3 Brake Mode Selector 4 Auto 2WD Relay 5 4WD/AWB Solenoid

1

2

1 1

4

Hand Held Tools 1 Rockbreaker Switch 2 Indicator Lamp 3 Rockbreaker Solenoid

Dedicated Quick Hitch 1 Hitch Enable Switch 2 Indicator Lamp 3 Alarm 4 Push Button 5 Push Button 6 Quick Hitch Relay 7 Quick Hitch Solenoid

FUSE B4

854

1

933

FUSE A5

FUSE A8

3

BR MODE SW

107

877

801

4

5

801

8

972

6

3

114

1

2

930

1855

7

10

OPERATOR HOLD-IN SWITCHES

4

AUTO 2WD RELAY

2

6

931

853

QUICK-HITCH RELAY

ROADBREAKER SOLENOID

932

7

3

ROTATION SOLENOID

GRAB SOLENOID

5

QUICK-HITCH SOLENOID

QUICK HITCH

HAND HELD TOOLS

AUTO 2WD RELAY

4WD/4WB

2WD/4WB

2WD/2WB

4 WB RELAY

4WD/AWB SOLENOID


A370070

Pole Planter 1 Selector Switch 2 Grab Solenoid 3 Rotation Solenoid

Issue 1

Section C

Electrics

Section C


19 - 12

19 - 12

H.S.C. RELAY

H.S.C. SOLENOID

LEVER 'HOLD' SOLENOID

ACCUMULATOR SOLENOIDS


867

5

3 4 H.S.C. RELAY

10

6

865 2

4

5

H.S.C. BUTTON

2

8

1 6

3

1856

8

2

8

3

132

132

TH

FROM 4 GEAR SELECTOR

818

FUSE A9

829

2

830

8

1

H.S.C. SWITCH

1

3

7

829

SRS SWITCH

7

SHOVEL RESET SWITCH

3

7

866

CROWD RAM PROXIMITY SWITCH

1851

1801

2

7

9

1857

844

2

1

FUSE B7

FUSE A1

101

A370071

Smooth Ride System (SRS) 1 Selector Switch 2 Accumulator Solenoids

9803/3270

Return To Dig (Shovel Reset) 1 Selector Switch 2 Ram Proximity Switch 3 Lever ‘hold in’ Solenoid

Hydraulic Speed Control 1 Supply from 4th Gear Selector 2 Selector Switch 3 Control Lever Push Button 4 Relay 5 HSC Solenoid

Issue 1

Section C 19 - 13

Electrics

Section C


19 - 13

Servo Command Pilot Circuit From Serial Number 495455 The circuit shown refers to the Servo option only, for the remainder of the circuit see the appropriate additional circuit. Main Components 1 Starter Switch 2 Return To Dig Switch 3 Servo Enable Switch 4 Sweeper Blower Switch 5 Shovel Limit Switch 6 Forward Seat Proximity Switch 7 Rearward Seat Proximity Switch 8 Mode Changeover Switch 9 Stabiliser Switch 10 Float Electro Magnetic Latch Coil 11 Return To Dig Electro Magnetic Latch Coil 12 Hydraulic Speed Control Switch 13 Transmission Dump Switch 14 Auxiliary Switch 15 Rear Horn 16 Quick Hitch Switch 17 Left Hand Amplifier 18 Left Hand Proportional Rocker Switch 19 Right Hand Amplifier 20 Right Hand Proportional Rocker Switch 21/22 Manifold Arms/Boom Changeover Solenoid 23/24 Manifold Shovel/Bucket Changeover Solenoid 25/26 Loader Solenoid 27/28 Auxiliary Solenoid 29/30 Excavator Left Hand Stabiliser Solenoid 31/32 Excavator Right Hand Stabiliser Solenoid 33 Manifold Left Hand Pilot Pressure Valve 34 Manifold Left/Right Hand Pilot Pressure Valve 35/36 Auxiliary Option Solenoid 37 Alarm

R20 R21 R22 R23

Stabiliser Lower Changeover Stabiliser Raise Changeover Stabiliser Lower Mode Changeover Stabiliser Raise Mode Changeover

On the illustration: B = Bottom T = Top H = Head R = Rod

Relays R1 Ignition R2 Front Seat R3 Front Mode Changeover R4 Rear Seat R5 Rear Mode Changeover R6 Spare R7 Dump Interlink (autoshift only) R8 Front Auxiliary Supply R9 Hammer Interlink R10 Stabiliser Isolator R11 Spare R12 Sweeper/Clam Changeover R13 Pilot Valve Changeover R14 Auxiliary/Clam 2 Changeover R15 Auxiliary/Clam 1 Changeover R16 Stabiliser/Clam 2 Changeover R17 Stabiliser/Clam 1 Changeover R18 Stabiliser/Auxiliary 1 Changeover R19 Stabiliser/Auxiliary 2 Changeover 9803/3270

Issue 1

Electrics

Section C 19 - 14

Section C


19 - 14

Servo Command Pilot Circuit From Serial Number 495455 To 499999 And From 920000 +12V

1 IGN SW 1816

D3

FROM TACHO ILLUMINATION

D1

1805

1851

5

7

6

LH AMPLIFIER 2

4

1826

1

1823

1825

1827

PROPORTIONAL SWITCH. LH STAB, AUX.OPT.

18

D9

4k

0.5k

930

921

929

AUTO DUMP RELAY

14

13

D7

17

0.5k

D8

0V

1V

10V

9V

D5

1833 1821

TO HSC RELAY

11 RTD

16 QUICK HITCH SWITCHES

1806

1811

D6

TRANS DUMP

FUSE 1A

1814

AUX FEED

875

1813

TO AUTO ECU

934

S3

RTD

10 FLOAT

2

1805

7

FUSE 5A

3

EXISTING +VE FEED TO HORN

AUX

4 6

7

931

101

12

934

PUMP DUMP

9

SWEEPER BLOWER SWITCH

L3

FROM TRANS DUMP RELAY

R7

1857

STAB

R

F

6

1804

1839

1840

7

1809

3

5

1824

2

112

8

1846

SERVO ENABLE 3 SWITCH

S1

2

S2

131

3

8

L2 8

6

5

830

L1

8

1808

012

2

MODE

844

1822

SERVO BUZZER

REAR HORN

FUSE 15A

FUSE 3A

FUSE 10A

R1

7

D4

37

101AB

12V +VE FEED

107

200V

1808

16

15

1824

19

FUSE 5A 1850

D11

1812 D2

1810

R3

R4

5

3

1807

R5

7

6

RH AMPLIFIER

4

1

2

D10

HAMMER SOLENOID FEED

20

870

870

R9

R10

R13

R12

R18

R17

R16

R15

R14

4k

0.5k

1844

R8

PROPORTIONAL SWITCH. CLAM, AUX, RH STAB.

1842

1807

1841

1843

R2

0V

R19

1V

0.5k 9V

10V

1845

1838 1834

1832

1849

1847 1807 947

1848

1 21

2 22

24

H

25 ARMS/BOOM CHANGEOVER VALVE

9803/3270

SHOVEL/BUCKET CHANGEOVER VALVE

T

B

26

LOADER VALVE

R

R

27

AUX VALVE

29

H

B

R

T

31

30

EXCAVATOR VALVE

H

B

R

33

AUX OPTION

5

6 T

AUX OPTION

1802

R.STAB

R8

1803

R.STAB

955

L.STAB

956

953

L.STAB H

28

954

957

AUX EXT DIP

958

AUX EXT DIP

4

3 23

CLAM

959

CLAM

960

1836

1831

R23

R22

1828

R21

FUSE 5A

R20

FUSE 5A

1837

1829

35

34

36

32

LH PILOT PRESSURE VALVE

LH/RH PILOT PRESSURE VALVE

AUX VALVE

GROUND

A370081 CAD 852/30231 sheet 7 iss 3

Issue 2

Section C

Electrics

Section C

Batteries

20 - 1

20 - 1

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.

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.

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:

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.

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

9803/3270

Issue 1

Section C 20 - 2

Electrics

Section C

Batteries

20 - 2

Testing - Specific Gravity 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.

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.

Specific Gravity at 15 °C (60 °F)

Ambient temperature up to 27 °C (80 °F) Ambient temperature above 27 °C (80 °F)

Fully Charged

Half Discharged

Fully Discharged

1.270 - 1.290 1.240 - 1.260

1.190 - 1.210 1.170 - 1.190

1.110 - 1.130 1.090 - 1.110

Battery 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.

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.

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.

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

A B

4

239510

Remedy

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.

Recharge and re-test. If tests still unsatisfactory renew battery.

3

CHECK: less than 10 Volts LOAD: less than 3 Volts

Indicates battery has been over-discharged and unlikely to recover. Renew battery.

4

CHECK: more than 11 Volts LOAD: 6 - 10 Volts steady

Charge battery which will probably recover.

9803/3270

Renew battery

Issue 1

Section C

Electrics

Section C

Wiring Harness Repair

25 - 1

25 - 1

Harness Repair Introduction

Tools Required

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.

892/00350 892/00349 892/00351 892/00352 892/00353

Butane Heater assembly Crimp tool Splice 0.5-1.5 mm (Red) Splice 1.5-2.5 mm (Blue) Splice 3.0-6.0 mm (Yellow)

1 1 50 50 50

Procedure 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.

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.

! 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

3

With the Butane heater assembly, 892/00350, seal the connection using the procedure on the next page.

....continued

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 .

7

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.

X

ELEC 2-3

S189530

9803/3270

Issue 1

Section C 25 - 2

Electrics

Section C


25 - 2

Procedure (cont'd) With the Butane Heater assembly 892/00350, seal the connection using the following procedure.

A

3.1 Remove the cap A from the end of the disposable gas cartridge B.

B

S189490/1

3.2 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

S189490/2

3.3 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.

S189490/3

3.4 Turn the small ring E so that the air holes at F are completely closed.

F E

S189490/4

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Issue 1

Section C 25 - 3

Electrics

Section C


25 - 3

Procedure (cont'd) 3.5 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

3.6 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.

F E

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. S189490/6

The heater can be used in two modes: 3.7 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).

G

Side wings G up (see fig at step 3.8), reflector head opening reduced. In this mode the heating is done only by the hot gas (use for dark coloured plastic splices).

S189490/7

3.8 To switch off the heater, turn the red ring D to the left (in the direction of the minus sign).

G

D

S189490/8

9803/3270

Issue 1

Section C

Electrics

Section C

Starter Motor

38 - 1

38 - 1

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).

Test 3 Connect the voltmeter between the solenoid terminal C and a good earth. Minimum permissible reading in 'start' position: 8.0V.

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.

C

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.

S151010

A low reading probably indicates a fault in the starter motor. 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

810C

600V

004

842

D

H

C

E

+

A B

B

A S151030

9803/3270

-

A215660

Issue 1

Section C

Electrics

Section C

Starter Motor

38 - 2

38 - 2

Starting Circuit Test (cont'd) Test 3b

Test 5

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.

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.

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.

A S151050

Test 5a

B S151040

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.

9803/3270

Issue 1

Section C 38 - 3

Electrics Starter Motor

Section C 38 - 3

S02043C

9803/3270

Issue 1

Section C

Electrics Starter Motor

38 - 4

Section C 38 - 4

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.

* On the 214Se machine, for access remove the engine oil dipstick tube E and throttle cable bracket F.

Assembly

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.

Servicing and Renewal

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.

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 page C/2-2) 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).

D S02303A

Check bronze bushes 32 and 34 for wear.

F E

A359370

9803/3270

Issue 2*

Section C

Electrics

Section C

39 - 1

Alternator

39 - 1

General Description

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.

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

Start the engine and run at maximum speed (see Technical Data). Meter should show maximum alternator output in Amps (see Technical Data).

a

Ensure that the battery negative terminal is connected to the earthing cable.

Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly.

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.

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.

c

d

e

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. During arc welding on the machine, protect the alternator by removing the moulded plug (or if separate output cables fitted, remove the cables). 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.

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.

a

Defective suppression capacitor.

b

Dirty slip rings or worn brushes.

c

Defective regulator.

d

Defective rectifier.

e

Open or short - circuited field (rotor) windings.

f

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.

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. Connect the leads to the meter and set the meter to the relevant range as follows.

9803/3270

S08346

Issue 1

Section C

Electrics

Section C

39 - 2

Alternator

39 - 2

9803/3270

Issue 1

Section C

Electrics

Section C

39 - 3

Alternator

39 - 3

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.

B A

Dismantling and Assembly When Dismantling Remove suppressor 2 (if fitted) by removing nut 1 and disconnecting lead E from terminal F. Unscrew bolts 3 and disconnect lead G from terminal H to remove the brush box and regulator assembly 4. If the brush length is less than 5mm (0.2 in.), new length 17mm (0.67 in.), or if spring pressure is less than 1.3N the brush box and regulator assembly must be renewed. Remove nuts and washers 5, bolts 6 and nuts 7. Remove slip ring end bracket 8. Carefully remove rectifier 10 and stator 11 as an assembly. Unsolder the interconnecting wires at X, Y, and Z only if renewing either of these components.

S099850A

Remove nut and washer 12 using an 8mm Allen key in the shaft hexagon hole to prevent rotation. If necessary, use a press to remove rotor 19 from the drive end bracket 17. Check the rotor poles and the inner faces of the stator for signs of rubbing, which indicates worn bearings. The drive end bearing is part of bracket 17 and cannot be removed separately. If requiring renewal, needle roller bearing 20 should be pressed out in the direction of the arrow. When Assembling Reverse the dismantling procedure, but note the following: Ensure that spacers 14,16, and 18 are correctly positioned as shown. Ensure that the slip rings J are clean and smooth, using extra fine glasspaper to rectify slight imperfections. Ensure that insulation bushes 9 and washers 5 are positioned as shown. Take care not to damage the brushes when fitting the brush box and regulator assembly. Torque Settings Item 3 5 6 7 12

Nm 2.7 4.1 3.4 5.4 60.0

9803/3270

kgf m 0.28 0.41 0.35 0.55 6.10

lbf ft 2.0 3.0 2.5 4.0 44.2

C

D S099850B

Issue 1

Section C

Electrics

Section C

39 - 4

Alternator

39 - 4

5 A 4

1 2

3

5

6

7 8

9 £

@

!

0

B

216870

9803/3270

Issue 1

Section C

Electrics

Section C

39 - 5

Alternator

39 - 5

Dismantling and Assembly - Magneti Marelli Type When Dismantling

When Assembling

Remove nuts 1 and cover 2.

Reverse the dismantling procedure, but note the following:

Check the protruding length of the brushes A. If this is less than 10 mm (0.4 in), the brushes must be renewed. This will involve renewal of the regulator and brush box assembly 6 as the brushes are not available separately.

Ensure that slip ring faces are clean and smooth, using very fine glasspaper if required. Do not use emery cloth.

Un-clip slip-ring shroud 3. Remove screw 4 and nuts 5 to remove regulator and brush box assembly 6. Do not separate the rectifier 7 from the slip-ring end bracket 8 as the gasket between them and its jointing paste provide a special heat conducting path which must not be disturbed. If further dismantling is required, note the positions of the six leads B and unsolder them from their locating tags on the rectifier. Using special socket 892/00882, remove nut 9, washer 10 and pulley 11. If necessary, press the drive end bearing, complete with the rotor 12, out of the bracket and stator assembly 13.

9803/3270

Ensure that stator connecting wires will not touch against the rotor. Lightly polish side faces of brushes to ensure free movement in brush box.

Torque Settings Item 1 4 5 (M5) 5 (M6)

Nm 3.0-4.0 2.0-2.5 1.7-2.3 3.6-5.1

Kgf m 0.3-0.4 0.2-0.25 0.2-0.23 0.4-0.5

lbf in 26-36 18-21 15-20 32-45

Item

Nm

Kgf m

lbf ft

9

70-90

7.2-9.1

52-66

Issue 1

Section C

Electrics

Section C

Harness Location

40 - 1

40 - 1

Cab and Chassis

3

4

2

6

7

ITEM

DESCRIPTION

1 2 3 4 5 6 7

Mainframe Harness Panel Harness Cab Harness Cab Roof Harness Solenoid Harness Rear Light Harnesses Engine Shut Off Harness

9803/3270

5

1

Note: The illustration shows a typical machine.

Issue 2

Section C

Electrics Harness Location

40 - 2

Section C 40 - 2

Servo Command

Item 1 2 3 4 5

Description Seat Loader Valve Block Auxiliary Valve Block Excavator Valve Block Manifold Block

9803/3270

Issue 1

Section C

Electrics Harness Location

40 - 3

Section C 40 - 3

Cab and Chassis - All Later Machines

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16

Description Chassis Harness Cab Panel Harness Cab Roof Harness Powershift Transmission Harness (not shown) Rear Cab (Sideshift) Harness Rear Lights (Sideshift) Harness Auxiliary Harness Head Lights Harness (not shown) Powershift Relay Harness Steer Mode Harness Air Conditioning Harness (not shown) Power Tool Extension Harness Servo Auxiliary Chassis Harness 3CX Link Connector (not shown) Strap Earth

9803/3270

Issue 1

Section D

Controls

Section D

i

i

Contents

Page No.

Backhoe Boom Lock - Removal and Replacement

2-1

Steering Column Dismantling and Assembly

4-1

Control Rods and Linkages Loader Valve Backhoe Valve

5-1 6-1

* Return To Dig Description Operation Ajustment Servo Command Joystick Control Lever - Removal and Replacement Shovel Reset (214e Machines)

9803/3270

7-1 7-1 7-1

8-1 10 - 1

Issue 4*

Section D

Controls

Section D

2-1

Boom Lock

2-1

Boom Lock - Removal & Replacement

4

9 8

2

2

3

7

0 5

@ !

6

1 4

B

E C A

D S261940

9803/3270

Issue 1

Section D

Controls

Section D

2-2

Boom Lock

2-2

Boom Lock - Removal & Replacement Removal

Replacement

1

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

Replacement is generally a reversal of the removal procedures, however, note the following:

2

Lower the backhoe to the ground and stop the engine.

3

Remove the boom lock casting:

After fitting the cable make sure that the operating lever is fully down. Adjust the bulk head fitting 11 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.

4

3.1 Remove cable ball stud 1 from casting and cable end.

To achieve correct boom stop setting:

3.2 Remove circlips 2

1

Lightly secure the boom stop A in its lowest position.

3.3 Remove pivot pin 3 and boom lock casting 4.

2

Raise the boom lock 4 using the control lever in the cab.

Remove the boom lock cable: 3

Fully close the boom ram (boom fully raised).

4.1 Loosen and remove screws 5 and take off the rear valance 6.

4

Engage the boom lock 4.

*

4.2 Remove the side console cover.

5

*

4.3 Remove E-clip 7, nut 8 and ball joint 9.

Make sure the engine is switched off and vent all residual pressure from the boom ram (move the backhoe control levers).

*

4.4 Remove nut 11, and clip 12 (under cab).

6

Adjust the boom stop A until there is 3 mm (1/8 in.) gap between the stop and the boom profile (as shown at B).

*

4.5 Remove cable 10. 7

Tighten bolt D and grubscrew C.

8

Tighten locknut E.

9

Fully close the boom ram (boom fully raised) and raise the boom lock 4 using the control lever in the cab.

10

If the boom lock does not release slacken the grubscrew C a further half turn. Slacken clamping bolt D, readjust the stop block and retighten bolt D. Lock the grubscrew and make sure the boom lock engages and disengages.

*

Torque Settings Item Nm D 476

9803/3270

kgf m 48

lbf ft 352

Issue 2*

Section D

Controls

Section D 4-1

Steering Column

4-1

C B

A

S266200

9803/3270

Issue 1

Section D 4-2

Controls Steering Column

Section D 4-2

Dismantling and Assembly On some machine models the steering column assembly can be tilted to improve operator reach and comfort levels. This type of assembly is referred to as a 'tilt column'. Non tilting columns are referred to as a 'fixed column'. Tilt columns have an additional universal joint fitted (item B) The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Dismantling Remove the front instrument housing and the steering column pedestal cover to gain access to the steering column. Note the electrical connections before disconnecting the components mounted on the housing. Bend back retaining tabs to permit removal of upper bearing 14. Note that on fixed column assemblies a thrust washer 14A is fitted It should be noted that the top and bottom bearings 14 and 15 housed in the outer column assembly are non serviceable parts. They may be removed for cleaning and inspection, but if the bearing(s) have failed, a new outer column assembly must be used.

When Assembling Press in bearing 15 until flush with end of outer column, and bearing 14 until it can be secured by the retaining tabs. On fixed column assemblies, crimp thrust washer 14A adjacent to the outer face of the inner bearing. Achieve minimum end-float (maximum permissible 2.0 mm 0.08in.) by selecting groove in spacer 9. Fit additional spacing washers 20 above set pin 19 if necessary. The coupling bolt 16 must be engaged with the cut-out in the shaft. Remove all dirt etc from the splined socket of steering valve A before fitting the column assembly. Install E-clip 24 as close as possible to the splines. Insert the shaft spline into the steer valve splined socket. Make sure that there is a 0.5 to 1.5 mm (0.020 to 0.060 in) gap between the splined shaft and socket, shown at C. The shaft must not touch the bottom of the splined socket. Apply JCB Lock and Seal to the threads of bolts 21 before fitting them.

To remove the steering column complete, remove bolts 11 and slacken nut 17. Then withdraw the column from the flexible coupling.

9803/3270

Issue 1

Section D

Controls

Section D 5-1

Control Rods and Linkages

5-1

C

A B

E D

A262000

9803/3270

Issue 1

Section D 5-2

Controls

Section D 5-2


Loader Valve The illustration shows the control rods and linkages for the loader control valve. Use the illustration and the parts descriptions as an aid to the correct assembly of the rods and linkages.

9803/3270

Item 1 2 3 4 5 6 9 10 11 13 14 15 17 18 A B C D E

Description Clevis Pin Safety Clip Control Rod Control Rod Lock Nut Bolt Universal Joint Bolt Loader Lever Gaiter Plug Lock Washer Spring Washer Lock Washer Thin Nut Nut Ball Joint Clevis Ball Joint

Remarks

1/2” UNFx1.1/2”

left hand thread left hand thread left hand thread

Issue 1

Section D

Controls

Section D 6-1


6-1

X

X

C

A

B D

F

G A262010

Control Plate CONTROL PLATE

9803/3270

Issue 1

Section D 6-2

Controls

Section D 6-2


Backhoe Valve The illustration shows the control rods and linkages for the backhoe control valve. Use the illustration and the parts descriptions as an aid to the correct assembly of the rods and linkages. Apply item 24 to the external threads of ball joints of items 3 and 4. When setting the backhoe levers, set initially with control lever plates parallel to mount plate (as shown at X). Then achieve the correct setting dimension S by equal adjustment of the left hand and right hand control rods. Setting Dimensions Control Pattern JCB + Pattern JCB X Pattern ISO + Pattern

Dim. ‘S’ ± 5mm (0.196 in.) 300 mm (11.810 in.) 336 mm 13.228 in.) 300 mm (11.810 in.)

Item 1 2 3 4 6 7 10 13 14 15 16 18 20 21 22 23 24 28 29 A B C D E F G

9803/3270

Description Stabiliser Lever Stabiliser Lever Control Rod Control Rod Gaiter Universal Joint Lock Washer Clevis Pin Safety Clip Bolt Lock Washer Lock Nut Plug Bearing Washer Safety Clip JCB Lock & Seal Lever Lever Thin Nut Nut Ball Joint Clevis Ball Joint U.J. Mount for Diagonal Pattern U.J. Mount for Plus Pattern

Remarks left hand right hand

A/R right hand left hand left hand thread left hand thread left hand thread

Issue 1

Section D

Controls

Section D 7-1

Return To Dig

7-1

3 2

1

A374040

9803/3270

Issue 1

Section D

Controls

Section D

Return To Dig

7-2

7-2

Description

Adjustment

This enables you to roll the shovel from the rolled forward position into the digging position quickly and easily.

Lower the loader arms and position the shovel in the required Return To Dig position.

When you select Return To Dig a switch on one of the loader arms cuts off the hydraulic pressure immediately the shovel reaches the correct angle for digging.

Switch OFF the engine but leave the ignition ON.

Operation

Adjust the rod with nuts 1 so that the LED on the proximity switches illuminates/extinguishes at this position.

To select Return To Dig Press the ‘return to dig enable’ switch A to the ON position, the switch will illuminate.

Switch the Return To Dig facility ON.

Adjust the proximity switch with nuts 2 to give a clearance 3 of 2 mm (0.08 in).

Pull the 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. When return to dig is no longer required press the enable switch to the OFF position.

A

S211471

9803/3270

Issue 1

Section D

Controls Servo Command

8-1

Section D 8-1

Joystick Control Lever Removal 1

Operate the controls to dissipate accumulator pressure and vent residual pressure.

2

Undo screws A, raise the seat arm and remove the joystick control lever.

3

Place a suitable container in position to catch hydraulic fluid, disconnect hydraulic hoses. The hoses should be labelled but if not label, this will ensure correct position when refitting.

4

Disconnect the electrical connectors B.

Replacement The procedure for fitting is the reverse of removal. On completion make sure that the control lever operates in the correct manner and there are no hydraulic leaks.

A

B

351810

9803/3270

Issue 1

Section D

Controls

Section D 10 - 1

Shovel Reset

10 - 1

H B F C

E G

H

A 2065mm

J

M K

L A320510

9803/3270

Issue 1

Section D

Controls Shovel Reset

10 - 2

Section D 10 - 2

214e Machines Only

Fitting

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.

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.

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

B

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.

C

A

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

9803/3270

Issue 1

Section E

Hydraulics

Section E

i

i

Contents

Page No.

Technical Data Hydraulic Pumps 1 - 1, 1 - 2, 1 - 3 Loader Valve 1 - 4, 1 - 5, 1 - 6, 1 - 7, 1 - 8 Backhoe Valve 1 - 9, 1 - 10 Auxiliary Valve 1 - 11, 1 - 12 Ancillary Equipment Stabiliser Check Relief Valve 1 - 13 Hydraulic Filter Element 1 - 13 Manifold Block (Servo Command) 1 - 13 Quick Release Couplings

2-1

Hydraulic Contamination

3-1

Fault Finding Standard Machines Servo Command Variable Flow Hydraulics Introduction to Hydraulic Schematic Symbols Schematics 3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines 3CX ‘S’ Series & 4CX Gear Pump Options 3CX ‘S’ Series Options Servo Command Pilot Circuit 3CXE (214E Series 3) Machines 214e Series 4 Machines * 214Se Series 4 Machines Variable Flow Hydraulics 4CX, 4CX Super Machines (7 Spool with options) 4CX, 4CX Super Machines (6 Spool with options) 4CX, 4CX Super Machines Hand Held Tools Machine Neutral Circuit Description 3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines 3CXE (214E) Machines Servo Pilot Circuit Variable Flow Hydraulics 4CX, 4CX Super Machines Hydraulic Pumps Pump Description Pump Flow Testing Removal & Replacement Dismantling & Assembly Dismantling & Assembly 3CXE (214E & 214e) M/c’s Model No. 6197C Dismantling & Assembly 3CXE (214E & 214e) M/c’s Model No. J101702 * Dismantling & Assembly 214Se M/c’s Model No. J101701 Variable Flow Hydraulics Pump Operation Pump Pressure/Flow Regulator Valve Operation Removal & Replacement Renewing Drive Shaft seal Dismantling and Assembly 9803/3270

4-1 4-5 4 - 10 5-1 6-1 6-3 6-3 6-5 6-7 6-8 6-9 7-1 7-3 7-5

8-1 9-1 9-2 9 - 10

10 - 1 10 - 2 10 - 3 10 - 4 10 - 8 10 - 10 10 - 11 10 - 20 10 - 21 10 - 27 10 - 28 10 - 29 Issue 6*

Section E

Hydraulics

Section E

ii

ii

Contents

Page No.

Flow and Pressure Testing Regulator Valve Adjustment Loader Valve Description Manual Servo Description Loader Valve Manual - Removal and Replacement Loader Valve Servo - Removal and Replacement Main Relief Valve - Description - Dismantling & Assembly Auxiliary Relief Valves & Load Hold Check Valves - Description - Dismantling & Assembly Unloader Valve Assembly - Description - Dismantling & Assembly Standard Spool Manual - Dismantling & Assembly Float Spool Manual - Dismantling & Assembly Electric Detent Spool Manual - Dismantling & Assembly Standard Spool Servo - Dismantling & Assembly Float Spool Servo - Dismantling & Assembly Electric Spool Servo - Dismantling & Assembly Loader Valve - Variable Flow Hydraulics Description Removal and Replacement Priority Inlet Section - Description of Operation - Dismantling and Assembly Auxiliary Service - Description of Operation - Dismantling & Assembly Loader Shovel Service - Description of Operation - Dismantling and Assembly Loader Lift Service - Description of Operation - Dismantling and Assembly Valve Section - Spool Seal Assembly

9803/3270

10 - 31 10 - 35 11 - 1 11 - 1A 11 - 2 11 - 2A 11 - 3 11 - 4 11 - 6 11 - 7 11 - 9 11 - 10 11 - 12 11 - 14 11 - 16 11 - 18 11 - 20 11 - 22

11 - 30 11 - 31 11 - 32 11 - 34 11 - 36 11 - 37 11 - 39 11 - 40 11 - 42 11 - 43 11 - 45

Loader Valve - 3CXE (214E) Machines Only Description Removal and Replacement Main Relief Valve - Description - Dismantling & Assembly

12 - 3 12 - 4

Loader Valve - 3CXE (214E) Machines Only Auxiliary Relief Valves & Load Hold Check Valves - Description - Dismantling & Assembly

12 - 6 12 - 7

12 - 1 12 - 2

Issue 6

Section E

Hydraulics

Section E

iii

iii

Contents Standard Spool - Dismantling & Assembly Float Spool - Dismantling & Assembly Loader Valve - Pressure Testing Main Relief Valve (M.R.V.) Unloader Valve Hydraulic Speed Control (HSC) Auxiliary Relief Valves

Page No. 12 - 9 12 -11

13 - 1 13 - 2 13 - 2 13 - 5

Backhoe Valve Manual Description 14 - 1 Servo Description 14 - 1A Backhoe Valve Manual - Removal and Replacement 14 - 2 Backhoe Valve Servo - Removal and Replacement 14 - 2A Manual - Dismantling & Assembly 14 - 3 Servo - Dismantling & Assembly 14 - 4A Auxiliary Relief Valves - Description - Dismantling & Assembly Hydraclamp Valve (Sideshift Machines) - Operation - Dismantling & Assembly Hoses and Pipes - Sideshift Valve - Centremount Valve

14 - 10 14 - 11

Backhoe Valve - Pressure Testing Auxiliary Relief Valves - Using Hand Pump

14 - 12

14 - 8 14 - 9

Auxiliary Valve Servo - Description - Removal and Replacement - Dismantling & Assembly

15 - 1 15 - 2 15 - 4

Variable Flow Hydraulics Description Testing Backhoe Valve - Removal and Replacement

16 - 1 16 - 2 16 - 3

Hose Burst Protection Valve Boom & Dipper Principle of Operation Loader Principle of Operation Checking Hose Burst Protection Valve Lowering A Load Removal and Replacement Dismantling & Assembly Pressure Testing - Loader Arms Lift Ram Servo Command Lowering the loader Arms and Boom Pilot Hose - Removal and Replacement * Pilot Pressure - Testing

9803/3270

14 - 5 14 - 6

17 - 1 17 - 5 17 - 9 17 - 9 17 - 10 17 - 11 17 - 13

18 - 1 19 - 1 19 - 3

Issue 7*

Section E

Hydraulics

Section E

iv

iv

Contents Rams Removal and Replacement - Loader Lift - Loader Shovel - Slew - Stabiliser (centremount) - Stabiliser (sideshift) - Dipper - Bucket Crowd - Boom Dismantling & Assembly - Loader Lift - Loader Shovel - Boom - Bucket - StabiIisers - Dipper - Slew Ram - Power Sideshift Ram JCB Ram Sealing Procedure

30 - 1 30 - 1 30 - 1 30 - 1 30 - 1 31 - 1 32 - 1 33 - 1 40 - 1

Hydraulic Oil Cooler Removal and Replacement

45 - 1

Smooth Ride System Technical Data Description Fault Finding Accumulator Charging Discharging Removal and Replacement Dismantling and Assembly

9803/3270

Page No.

20 - 1 21 - 1 22 - 1 23 - 1 23 - 2 24 - 1 25 - 1 26 - 1

50 - 1 50 - 2 51 - 1 52 - 1 52 - 1 52 - 2 52 - 3

Issue 4

Section E 1-1

Hydraulics

Section E

Technical Data

1-1

Hydraulic Pumps Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement: Pump section 1 (mounting flange end) Pump section 2 * Flow at 2200 rev/min and system pressure (90% min displacement): Pump section 1 (mounting flange end) Pump section 2 Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight

Double pump/4070H Anti-clockwise Chassis (driveshaft driven) cc/rev cu in/rev 33 2.01 23 1.40 litres/min UK gal/min 65.3 14.4 45.5 10.0 3000 rev/min 500 rev/min 24kg (53 lbs)

Model/Reference Rotation (viewed on end of driveshaft) Mounting Theoretical displacement: Pump section 1 (mounting flange end) Pump section 2 * Flow at 2200 rev/min and system pressure (90% min displacement): Pump section 1 (mounting flange end) Pump section 2 Maximum speed @ pressure P1 Minimum speed @ pressure P1 Approximate Weight

Double pump/83103 Anti-clockwise Chassis (driveshaft driven) cc/rev cu in/rev 36 2.19 26 1.59 litres/min UK gal/min 71.3 15.7 51.5 11.3 3000 rev/min 500 rev/min 23.8kg (52 lbs)


Double pump/7441N Anti-clockwise Chassis (driveshaft driven) cc/rev cu in/rev 41 2.50 26 1.59 litres/min UK gal/min 81.2 17.9 51.5 11.3 3000 rev/min 500 rev/min 24.5kg (54 lbs)


Double pump/4071F Anti-clockwise Chassis (driveshaft driven) cc/rev cu in/rev 41 2.50 29 1.77 litres/min UK gal/min 81.2 17.9 57.4 12.6 3000 rev/min 500 rev/min 24.5kg (54 lbs)

9803/3270

US gal/min 17.2 12.0




Issue 4*

Section E 1-2

Hydraulics

Section E

Technical Data

1-2

Hydraulic Pumps (continued) Model/Reference Single pump/6197C Rotation (viewed on end of driveshaft) Anti-clockwise Mounting Chassis (driveshaft driven) Theoretical displacement 50 cc/rev; 3.05 cu in/rev * Flow at 2200 rev/min and system pressure (90% min displacement): 99 litres/min; 21.8 UK gal/min; 26.2 US gal/min Maximum speed @ pressure P1 3000 rev/min Minimum speed @ pressure P1 500 rev/min Approximate Weight 11.75kg (25.9 lbs) Model/Reference Single pump/J101702 Rotation (viewed on end of driveshaft) Anti-clockwise Mounting Chassis (driveshaft driven) Theoretical displacement 51 cc/rev; 3.05 cu in/rev Flow at 2200 rev/min and system pressure (95% min displacement): 105 litres/min; 23.1 UK gal/min; 27.7 US gal/min Maximum speed @ pressure P1 3000 rev/min Minimum speed @ pressure P1 500 rev/min Approximate Weight 13 kg (28.6 lbs)

*

Model/Reference Single pump/J077701 Rotation (viewed on end of driveshaft) Clockwise Mounting Engine Theoretical displacement 51 cc/rev; 3.11 cu in/rev Flow at 2200 rev/min and system pressure (95% min displacement): 105 litres/min; 23.1 UK gal/min; 27.7 US gal/min Maximum speed @ pressure P1 3000 rev/min Minimum speed @ pressure P1 500 rev/min Approximate Weight 14 kg (30.8 lbs)

9803/3270

Issue 4*

Section E 1-3

Hydraulics

Section E

Technical Data Variable Flow Hydraulics

1-3

Hydraulic Pumps (continued) Machine models applicable to Type Variable Displacement Reference Rotation (viewed on end of driveshaft) 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/in2 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

4CX, 4CX Super A10VO - 978753 Anti-clockwise Chassis (driveshaft driven) Maximum permitted - 5 bar; 72.5 lbf/in2 230 bar; 3335 lbf/in2 20 bar; 290 lbf/in2 232 bar; 3364 lbf/in2 270 bar; 3915 lbf/in2 74cc/rev; 4.5 in3/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. Refer to page E/10-33 for more detail.

S273090

9803/3270

Issue 3

Section E

Hydraulics

Section E

Technical Data

1-4

1-4

Loader Valve Machine Models Applicable to: 3CX, 4CX, 214, 215, 217 and ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Arms lift service 2 Shovel service 3 Auxiliary (optional) 4 Pump section 1 - inlet 5 Pump section 2 - inlet 6 Pressure test port 7 Unloader Assembly

ITEM 8 9 10 11 12 13 14

Relief Valve Operating Pressures: * Main Relief Valve (M.R.V.) * Unloader Valve Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Shovel Ram Rod side

DESCRIPTION Unloader solenoid Auxiliary relief valve Tank port High pressure carry-over (HPCO) port Service ports Load hold check valve assemblies Data plate

bar 236 - 241 207 - 214

kgf/cm2 240 - 245 207 - 211

lbf/in2 3420 - 3500 3000 - 3100

172 - 179 310 - 317

176 - 183 316 - 323

2500 - 2600 4500 - 4600

* Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. Weight 25kg (55lbs) (3 spool) TBA (2 spool)

1

2

3

7 9

@

@

8 @

6 $

5

£ 0

4

@

@

!

@

9

A262160

9803/3270

Issue 3*

Section E

Hydraulics

Section E

Technical Data

1-5

1-5

Loader Valve Machine Models Applicable to: 3CXE, 214E Series 3 Valve Block Identification: ITEM DESCRIPTION 1 Arms lift service 2 Shovel service 3 Pump inlet 4 Tank port 5 Auxiliary relief valve 6 High pressure carry-over (HPCO) port 7 Service ports

Relief Valve Operating Pressures: * Main Relief Valve (M.R.V.) * Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Shovel Ram Rod side

bar 228 - 235

kgf/cm2 233 - 239

lbf/in2 3300 - 3400

172 - 179 310 - 317

176 - 183 316 - 323

2500 - 2600 4500 - 4600

* Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. Weight: 8kg (17.6lbs)

2 1

5

7

7

4

7

7

3

6

5 A262420

9803/3270

Issue 4*

Section E

Hydraulics

Section E

Technical Data

1-6

1-6

Loader Valve Machine Models Applicable to: 214e Series 4 Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary service 2 Arms lift service 3 Shovel service 4 Pump inlet 5 Tank port 6 Auxiliary relief valve 7 High pressure carry-over (HPCO) port 8 Service ports

Relief Valve Operating Pressures:

* Main Relief Valve (M.R.V.) * Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side Shovel Ram Rod side

bar 228 - 235

kgf/cm2 233 - 239

lbf/in2 3300 - 3400

172 - 179 310 - 317

175 - 183 316 - 323

2500 - 2600 4500 - 4600

* Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. * Weight: 10 kg (22 lbs)

3

2 1

6 8 8 8

5

8 8 8

4

7

6 A313430

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Technical Data Servo Command

1-7

1-7

Loader Valve Machine Models Applicable to: 3CX, 4CX, 4CN, 214, 215, 217 and ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Arms lift service 2 Shovel service 3 Auxiliary (optional) 4 Pump section 1 - inlet 5 Pump section 2 - inlet 6 Pressure test port 7 Unloader Assembly

Relief Valve Operating Pressures: Main Relief Valve (M.R.V.) @ 1500 RPM Unloader Valve Auxiliary Relief Valves (A.R.V.) Loader Shovel Ram Head Side (service port B) Shovel Ram Rod Side (service port A)

ITEM 8 9 10 11 12 13 14 15

DESCRIPTION Unloader solenoid Auxiliary relief valve Tank port High pressure carry-over (HPCO) port Service ‘A’ ports Load hold check valve assemblies Service ‘B’ ports Main relief valve (MRV)

bar 236 - 241 207 - 214

kgf/cm2 240 - 245 211 - 218

lbf/in2 3420 - 3500 3000 - 3100

172 - 175 310 - 314

175 - 178 316 - 320

2500 - 2550 4500 - 4550

Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. Weight 34 kg (75 lbs)

1

2

3

7 9

5

6

4

8

@

@

@

£

£

£

$

$

$

£

0

!

9 % A337490

9803/3270

Issue 1

Section E

Hydraulics

Section E

Technical Data Variable Flow Hydraulics

1-8

1-8

Loader Valve Machine Models Applicable to: 4CX, 4CX Super

Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary (optional) service 2 Shovel service 3 Arms lift service 4 Pump inlet 5 Tank port 6 Load sense port (to pump) 7 Priority load sense port (from steer unit)

ITEM 8 9 10 11 12 13

Relief Valve Operating Pressures: Priority Relief Valve† Auxiliary Relief Valves (A.R.V.) @ 0.5gal/min (1.9 litres/min) Shovel Ram Head Side Shovel Ram Rod side

DESCRIPTION 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 †

bar

* 170 - 176 170 - 174

* 306 - 314

kgf/cm2 173 - 179

lbf/in2 2450 - 2550

173 - 177 312 - 320

2465 - 2520 4450 - 4550

† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2, this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.

Weight: 2 Spool - TBA kg (TBA lbs) 3 Spool - TBA kg (TBA lbs)

3

1

2

!

9

0

0

0

0

0

0

4 5 8

@

7

6

£

A273670

9803/3270

Issue 1

Section E

Hydraulics

Section E

Technical Data

1-9

1-9

Backhoe Valve Machine Models Applicable to: 3CX, 3CXE, 4CX, 214, 214E, 215, 217 and ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Bucket crowd 2 Dipper † 3 Stabiliser 4 Stabiliser 5 Boom † 6 Slew 7 Auxiliary relief valve

ITEM 8 9 10 11 12 13 14

DESCRIPTION Tank port High pressure carry-over (HPCO) port Service ports Load hold check valve assemblies Make-up check valve assembly Inlet port Hydraclamp solenoid

Relief Valve Operating Pressures: Boom Ram Head Side Boom Ram Rod Side Bucket Ram Head Side Centremount (17' , 15’ 6” backhoe - except knuckle) Centremount (14' backhoe, 15’ 6” backhoe with a knuckle fitted) Sideshift Bucket Ram Rod Side (Machines with Rockbreaker only) Dipper Ram Head Side Dipper Ram Rod Side Slew Left and Right

bar 248 - 255 345 - 352

kgf/cm2 253 - 260 351 - 358

lbf/in2 3600 - 3700 5000 - 5100

310 - 317 248 - 255 248 - 255 248 - 255 248 - 255 248 - 255 262 - 269

316 - 323 253 - 260 253 - 260 253 - 260 253 - 260 253 - 260 267 - 274

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: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. † 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.

1

2

3

4

7

8

0

0

0

0

5

6

7

7

0

0

!

!

!

!

!

!

0

0

0

0

0

0

7

7

7

7

£ @

$

9 A262520

9803/3270

Issue 1

Section E

Hydraulics

Section E


1 - 10

1 - 10

Backhoe Valve Machine Models Applicable to: 3CX, 3CXE, 4CX, 4CN, 214, 214E, 215, 217 and ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Bucket crowd 2 Dipper † 3 Stabiliser 4 Stabiliser 5 Boom † 6 Slew 7 Auxiliary relief valve 8 Tank port

ITEM 9 10 11 12 13 14 15 16

Relief Valve Operating Pressures: Boom Ram Head Side Boom Ram Rod Side Bucket Ram Head Side Centremount (17' , 15’ 6” backhoe - except knuckle) Centremount (14' backhoe, 15’ 6” backhoe with a knuckle fitted) Sideshift Bucket Ram Rod Side (Machines with Powerbreaker only) Dipper Ram Head Side Dipper Ram Rod Side Slew Left and Right

DESCRIPTION Inlet port Service ‘B’ ports Load hold check valve assemblies Service ‘A’ ports Clamp port Clamp solenoid drain Hydraclamp solenoid High pressure carry over (HPCO) port bar 248 - 255 345 - 352

kgf/cm2 253 - 260 352 - 358

lbf/in2 3600 - 3700 5000 - 5100

310 - 317 248 - 255 248 - 255 248 - 255 248 - 255 248 - 255 262 - 269

316 - 323 253 - 260 253 - 260 253 - 260 253 - 260 253 - 260 267 - 274

4500 - 4600 3600 - 3700 3600 - 3700 3600 - 3700 3600 - 3700 3600 - 3700 3800 - 3900

Weight: 52.5 kg (116 lbs) † System shown is for ISO plus pattern.

2 1

8

3

4

7

5

6

7

7

0

0

0

0

0

0

!

!

!

!

!

!

@

@

@

@

@

@

^

9 %

$ 7

9803/3270

£

3

4

7

7 A337330

Issue 3

Section E

Hydraulics

Section E

Technical Data

1 - 11

1 - 11

Auxiliary Valve Machine Models Applicable to: 3CX, 3CXE, 4CX, 214, 214E, 215, 217 and ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary Spool 2 Inlet port 2 Outlet port 3 Auxiliary relief valve 4 High pressure carry-over (HPCO) port 7 Service ‘A’ ports 8 Service ‘B’ ports Relief Valve Operating Pressures: 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

bar 138 - 145 207 - 214 138 - 145 207 - 214 138 - 145 207 - 214 207 - 214 207 - 214

kgf/cm2 141 - 148 211 - 218 141 - 148 211 - 218 141 - 148 211 - 218 211 - 218 211 - 218

lbf/in2 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 2000 - 2100 3000 - 3100 3000 - 3100 3000 - 3100

138 - 150

141 - 153

2000 - 2200

Weight: TBA kg (TBA lbs)

9803/3270

Issue 2

Section E

Hydraulics

Section E


1 - 12

1 - 12

Auxiliary Valve Machine Models Applicable to: 3CX, 4CX, 4CN, 214, 215, 217 and ‘S’ Series Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary 1 service 2 Auxiliary 2 service 3 Inlet port 4 Outlet port 5 Auxiliary relief valve 6 High pressure carry-over (HPCO) port 7 Service ‘A’ ports (head side) 8 Service ‘B’ ports (rod side) Relief Valve Operating Pressures: Auxiliary Relief Valves (A.R.V.) Auxiliary 1 ‘A’ port ‘B’ port Auxiliary 2 ‘A’ port ‘B’ port

bar

kgf/cm2

lbf/in2

138-145 207-214

141-148 210-218

2000-2100 3000-3100

207-214 207-214

210-218 210-218

3000-3100 3000-3100

Note: The pressure testing and adjustment MUST be carried out as detailed on pages E/13-1 to E/13-8. Weight: 12 kg (26.5 lbs) 2 spool

2

1

5

5

7

7

4

6 8

5

8

3

5 A337500

9803/3270

Issue 3

Section E

Hydraulics

Section E

Technical Data

1 - 13

1 - 13

Ancillary Equipment Stabiliser Check Valve Relief Valve (Centremount M/c's) Relief Valve Operating Pressures: Check Valve

bar 303 - 317

kgf/cm2 309 - 323

lbf/in2 4400 - 4600

Relief Valve Operating Pressures: By-pass pressure

bar 3.0 - 3.5

kgf/cm2 3.0 - 3.6

lbf/in2 43.5 - 51

Manifold Block (Servo Command)

bar 30

kgf/cm2 30.5

lbf/in2 435

Weight: 1.0 kg (2.2 lbs)

Hydraulic Filter Element

1 2 3

Pressure reducing valve (preset) Port change over valves, direct operated spool type Port change over valves, direct operated seat type Solenoids, 12V DC nominal, coils rating - 26 Wattts 4 Accumulator Pre charge pressure (nitrogen) 5 Filter, non bypass type 50mm A/F cap 6 Manual override 7 Test point 8 Auxiliary pilot connection 9 Right hand pilot connection 10 Left hand pilot connection 11 Tank connections 12 Inlet connection A1 Pilot connections B1 Pilot connections C1 Pilot connections

6

6

3

4

0.24 litre 5.0 5.1 10 micron absolute

6

1

3

6

2

2

6

2

2 B3

B4

12

7

FILTER

6

B2

B1

0

72.5

C3

C2

C1

C4

5 8

9

!

A1

A2

A3

A4 347280

9803/3270

Issue 1

Section E 2-1

Hydraulics

Section E

Quick Release Couplings

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, please read the correct fitting and releasing procedures before installing or removing any optional attachment fitted with quick release couplings.

2-1

! WARNING Hydraulic fluid at pressure can injure you. Make 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 before connecting or removing hoses - refer to the appropriate attachment information in this section.

Quick Release Couplings - Do's & Don'ts Connecting Quick Release Couplings DO wipe the two faces of the coupling and make sure they are clean before connecting.

1

Remove any residual hydraulic pressure trapped in the service line hose.

DO make sure the outside sleeve (female coupling) is pulled back when disconnecting.

2

Wipe the two faces of the male and female couplings and make sure they are clean.

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'.

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.

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.

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.

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 try to dismantle the couplings - they are non serviceable parts. If a coupling is damaged it should be replaced with a new one.

A

C

E

D

B

S169490

9803/3270

Issue 1

Section E 3-1

Hydraulics

Section E

Hydraulic Contamination

3-1

Hydraulic Fluid Quality

Contaminant Standards

Construction machinery uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing.

Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns.

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.

1 micron=

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 greatly effect the performance and life of hydraulic 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.

0.001 mm (0.0000394 in)

Listed below are a few typical comparisons:Red Blood Cell Human Hair Grain of Salt

= 8 microns (0.008 mm, 0.000315 in) = 70 microns (0.07 mm, 0.00275 in) = 100 microns (0.1 mm, 0.00394 in)

Smallest particle visible to the naked eye is 40 microns (0.00157) approximately. Standards will often be quoted to ISO (International Standards Organisation) for which literature can be 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. It must be serviced to the requirements of the machine Service Schedules.

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, fibres, metallic particles, welding scale, sealing materials and wear particles etc.

2

Liquid - usually water and incompatible oils and greases.

3

Gases - Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.

These contaminants can appear during manufacture, 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.

S168050

9803/3270

Issue 2

Section E

Hydraulics

Section E

4-1

Fault Finding

4-1



Introduction

4-1

Lack of power in all hydraulic functions

4-1

All hydraulic rams slow to operate

4-2

One hydraulic service fails to operate or is slow to operate

4-2

The engine tends to stall when the hydraulics are under load

4-2

A spool is sticking

4-3

Leaking Oil Seal (Control Valves)

4-3

Ram creep

4-3

Hydraulic oil becomes too hot

4-4

Steering fails to operate or is stiff to operate Steering fails to respond to selected mode

Fault 1

Lack of power in all hydraulic functions.

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 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


2


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.

4-4

4-4

Probable Cause

Action

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, replace as required.

Engine performance.

Check engine performance, see transmission section for stall speed test procedures.

Main relief valve (MRV) setting incorrect.

Check and adjust as required.

Low pump flow.

Check pump flow, if required service or replace pump.

Hydraulic tank breather

Clean or replace the breather

Tank filter by-pass valve

Check condition of hydraulic filter

Unloader valve pressure setting too high

Check pressure setting of the unloader valve.

..... continued

9803/3270

Issue 1

Section E

Hydraulics

Section E

4-2

Fault Finding

4-2

Fault 2

3

All hydraulic rams slow to operate.

One hydraulic service fails to operate or is slow to operate.

Probable Cause

Action

Neutral circuit or low pressure lines leaking, damaged, trapped or kinked.

Check pipe lines and replace as required.

Low pump flow.


Priority valve operating.

Check if the priority valve is sticking, rectify as required.

Main relief valve (MRV) setting incorrect.


Unloader valve

Check if unloader valve is sticking, i.e. dumping flow from pump section P2.

Tank filter by-pass valve

Check condition of hydraulic filter

Hydraulic tank breather

Clean or replace the breather

Associated service pipe lines , leaking damaged, trapped or kinked.

Check hoses, replace as required.

Associated ram leaking.

Complete ram leakage check, replace seals 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'.

Check valve malfunctioning (if fitted, e.g. stabiliser circuit)

Test check valve, rectify as required.

Hose burst protection valve (if fitted) malfunctioning.

Test HBPV, service as required.

Piston rod is bent

Replace piston rod, check pressure settings of MRV and ARV. Check that associated pivot pins are adequately greased

4

The engine tends to stall when hydraulics are under load.

9803/3270

M.R.V setting incorrect.


Poor engine performance.

Check engine performance, see transmission section for stall speed test procedures.

Unloader valve pressure

Check pressure setting of the setting too high unloader valve.

Issue 1

Section E

Hydraulics

Section E

4-3

Fault Finding

4-3

Fault 5

6

7

A spool is sticking.

Leaking Oil Seal (Control Valves)

Ram creep.

Probable Cause

Action

Oil temperature abnormally high.

Check for correct fluid, see Lubricants and Capacities. Check oil cooler and grille for blockage.

The hydraulic fluid is dirty.

Clean the tank strainer. If strainer badly clogged, drain and flush hydraulic system Fill with clean hydraulic fluid.

The service pipe connection is over tightened.

Check tightening torque.

The valve housing was twisted during installation.

Loosen retaining bolts and tighten to correct torque figures.

Pressure too high.

Check system pressure.

A control linkage is bent

Disconnect the linkage. Repair the linkage if possible, or fit a new one

A spool is bent

Dismantle the control valve. Renew spool as necessary.

A return spring is broken.

Renew as necessary.

A return spring or cap is out of alignment.

Remove the cap, check that the spring is in the correct position. Refit cap and torque tighten bolts

Temperature distribution within control valve not uniform.

Warm the entire system up before using service.

Paint or dirt on the seal face.

Remove the seal and clean.

The back pressure in the valve circuit is excessively high.

Check circuit pressures. Adjust if possible. Otherwise investigate thoroughly.

Spool damaged.

Dismantle. Inspect all parts. Renovate or renew as necessary.

The seal is not secured.

Clean the seal and tighten the retaining bolts to the correct torque.

The seal is cut or damaged.

Fit a new seal.

Associated ram or pipe lines from ram leaking.

Check and rectify as required.

Check valve malfunctioning (if fitted, e.g. stabiliser circuit)

Test check valve, rectify as required.

Associated valve section spools leaking.

Rectify, check for contamination.

Associated ARV leaking

Rectify, check for contamination

.

..... continued

9803/3270

Issue 1

Section E

Hydraulics

Section E

4-4

Fault Finding

4-4

Fault 8

9

Hydraulic oil becomes too hot

Steering fails to operate or is stiff to operate

Probable Cause

Action

Oil cooler obstructed

Remove debris from cooler fins

Restriction in neutral circuit lines

Check hoses, replace as necessary

Hydraulic filter clogged and by-pass valve not working

Change hydraulic filter

Tyres not inflated to correct pressure

Inflate tyres to correct pressure



Low pump flow.


Leaks in the relevant hoses or component connections

Check hoses and connections for leaks.

Steer relief valve set incorrectly

Check pressure setting of steer unit relief valve, adjust as required.

Priority valve not operating correctly

Check if the priority valve is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor connection.

Steer mode valve not operating correctly

Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required

Mechanical failure

Check for damaged axle components, such as rams, trackrods, linkages etc. Check for damaged steer unit components. Steering column and associated components not set correctly.

10 Steering fails to respond to selected mode

Selector switch faulty

Check selector switch, replace as required

Proximity switches not operating correctly

Check setting of proximity switches, reset or replace switches as required.


Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.

9803/3270


Check hoses and connections for leaks

Electrical failure

Check relevant electrical connectors, if problem still persists, do a wiring ontinuity check on relevant circuits.

Issue 1

Section E

Hydraulics

4-5


Section E

Fault Finding Servo Command Introduction Page No.

4-5

Introduction

4-5

This section details the possible faults that may be found with the loader, excavator and manifold valve blocks. The faults listed only appertain to servo command valve blocks.

No servo controls

4-5

Refer to hydraulic schematic in this section.

Lack of power in all hydraulic functions

4-5

1

One hydraulic service fails to operate or is slow to operate


4-5

2

No hydraulic functions on left hand joystick

4-5


Services slow to operate

4-5

3


One hydraulic service fails to operate

4-5

4

Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

5


6


7

Replace any seals such as 'O' rings before assembling hydraulic components.

Fault 1

No servo controls

Probable Cause No pilot pressure

Action As step 2 See, Servo Command Electrical Fault Finding, Section C.

2

Lack of power in all hydraulic functions or all services slow to operate.

Pilot pressure low.

Carry out pilot pressure check. Check pilot filter is not blocked. Pilot pressure reducing valve set incorrectly, adjust as required.

Sticking left/right hand pilot valve

Check free movement of manifold pilot valve.

3

No hydraulic functions on left hand joystick, right hand OK

Left hand pilot valve sticking

Check free movement of manifold pilot valve.

4

Services slow to operate

Cold hydraulic oil

Operate to working temperature.

5

One hydraulic service fails to operate or is slow to operate.

Pilot pressure low.

As step 2.

Sticking changeover valve

Check free movement of relevant valve in manifold block. Check pilot pressure to valve block.

Sticking valve block spool

Check exhaust pressure at service spool. Remove and check free movement of service spool. If spool is solenoid operated, see Servo Command Electrical Fault, Section C.

9803/3270

Issue 1

Section E

Hydraulics Fault Finding Variable Flow Hydraulics

4 - 10


Introduction

4 - 10

High or low system pressure

4 - 10

Pump stays at high pressure

4 - 10

Pressure or flow obtained at one port only

4 - 10

No pressure or flow at either port

4 - 10

High work port leakage

4 - 10

Leaks between sections

4 - 11

Sticking spool

4 - 11

Detent will not hold

4 - 11

Electrical detent will not hold

4 - 11

This section details the possible faults that may be found with the loader and backhoe valve blocks. The faults listed only appertain to valve blocks fitted on variable flow hydraulic machine systems (Rexroth valves). 1


2


3


4


5


6


7


* Poor performance, slow operating speed and/or

PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:

4 - 10


low maximum stall speed

Section E

4 - 11

High or Low system pressure. 1) Wrong pressure and/or flow regulator valve settings. 2) Loss of pilot signal due to shuttle failure. 1) Readjust regulator valves. 2) Operate individual services to determine which shuttle is at fault, (see page E/16-2).


Pump stays at high pressure. 1) Sticking main spool. 2) Sticking compensator spool. 1) See ‘Sticking Spool’ guide. 2) Remove & clean compensator spool.


Can only obtain pressure or flow at one port. 1) Dirt in primary shuttle or damaged o-ring. 1) Remove & clean shuttle, inspect o-ring and replace if required.


No pressure or flow at either port. 1) Dirt in secondary shuttle. 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.


High work port leakage. 1) Spool not centred. 2) Dirt in port relief valve. 1) Check centring springs. 2) Remove & clean relief valve.

9803/3270

Issue 3*

Section E 4 - 11

Hydraulics Fault Finding Variable Flow Hydraulics

Section E 4 - 11

....continued PROBLEM: POSSIBLE CAUSE: CORRECTIVE ACTION:

Leaks between sections. 1) Missing or cut seals. 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. 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.

CORRECTIVE ACTION:


Mechanical detent will not hold. 1) Broken detent shaft. 1) Remove detent & inspect.


Electrical detent will not hold. 1) Current broken. 1) Check current going into detent.


Poor performance, slow operating speed and/or low maximum stall speed. 1) Blocked flow regulator spool. 1) Flow check, remove and clean flow regulator valve, see page E/10-36.

*

9803/3270

Issue 2*

Section E

Hydraulics

Section E

5-1

5-1

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.

Pumps & Motors

Fixed capacity pump one direction of flow

Fixed capacity pump two directions of flow

Variable capacity pump one direction of flow

General (Basic & Functional Symbols) Variable capacity pump two directions of flow

Spring

Flow restriction affected by viscosity

Fixed capacity motor one direction of flow

Direction of flow

Indication of rotation

Fixed capacity motor two directions of flow Indication of direction and paths of flow Variable control

A189660

Variable capacity motor one direction of flow

Variable capacity motor two directions of flow

Rams

Single acting

Double acting

Double ended

A189670 Double acting with damping at rod area end

9803/3270

A189680

Issue 1

Section E

Hydraulics

Section E

5-2

5-2

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

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

Throttling orifice normally open

Non - return valve

Relief valve Non - return valve with back pressure spring

Pilot operated non - return valve A189690

9803/3270

Variable restrictorA189700

Issue 1

Section E

Hydraulics

Section E

5-3

5-3

Introduction to Hydraulic Schematic Symbols (cont'd) Energy Transmissions and Conditioning Working line, return or feed

Reservoir - return line above fluid level

Pilot control

Drain lines

Reservoir - return line below fluid level

Flexible pipe

Header tank

Pressure sealed tank

Line junction

Accumulator Crossing lines

Filter or strainer

Air bleed

Water trap

Line plugged, also pressure test point

Cooler - with no indication of coolant flow

Line plugged with take off line

Cooler - indicating direction of coolant flow

Quick release couplings - connected

Heater

A189710

A189720

Quick release couplings - disconnected 9803/3270

Issue 1

Section E

Hydraulics

Section E

5-4

5-4

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)

9803/3270

S189730

S189740

Issue 1

Section E

Hydraulics

Section E

5-5

5-5

Introduction to Hydraulic Schematic Symbols (cont'd)

FIG 1

Control Valves

Position 1

Position 2

Position 3

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 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. Port 1

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.

Port 3

FIG 3

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.

Port 2

Port 4

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 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 5

A189760

9803/3270

Issue 1

Section E

Hydraulics

Section E

5-6

5-6

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.

Example Circuit Key A B C D E F G

Hydraulic Tank Strainer Fixed Displacement Pump Relief Valve Spool One Way Valve Double Acting Hydraulic Ram

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

G D E F

A189770

9803/3270

Issue 1

Section E 6-1

Hydraulics Schematics

* 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. Component Key *C Tank Cap * JJ Connections (as applicable) P1 Pump, Main Section P2 Pump, Secondary Section P2A Pressure Test Point (auxiliary & unloader) S Suction Line T Tank *M Connections (as applicable) * MM Quick Release Couplings 1A Neutral Circuit Line 1B Neutral Circuit Line 2A Neutral Circuit Line 3 Loader Valve Block 3A Pressure Test Point (M.R.V.) 3B Unloader Pilot Valve 3C Loader Lift Ram Spool 3D Loader Shovel Ram Spool 3E Clamshovel Spool 3F Shovel Ram Head Side A.R.V. 3G Shovel Ram Rod Side A.R.V. 3J Load Hold Check Valve 3L Unloader Valve Spool 3M Main Relief Valve 3N Unloader Check Valve 3Q 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. 4A Slew Spool 4B Boom Spool 4C Stabiliser Spool 4D Stabiliser Spool 4E Dipper Spool 4F Bucket Spool 4G Hydraclamp Valve (Sideshift Machines Only) 4H Slew A.R.V. 4J Slew A.R.V. 4K Boom Ram Rod Side A.R.V. 4L Boom Ram Head Side A.R.V. 4M Dipper Ram Head Side A.R.V. 4N Dipper Ram Rod Side A.R.V. 4P Bucket Ram Head Side A.R.V. *5 Auxiliary Valve Block (foot operated) * 5A Auxiliary Spool * 5B A.R.V. * 5C A.R.V. 6 In-tank Filter 6A Filter By-pass Valve 6B Suction Strainer 7 Priority Valve *8 Filter * Fitted from machine s/no. 475518 or see bulletin 2/218. *9 Filter * Fitted from machine s/no. (twin pump) 473385 and (single pump) 473444 or see bulletin 2/218. * 10 Diverter Valve (hammer only) 9803/3270

Section E

* 11 * 12 13 * 14 * 15 * 16 26 31 32 33 34 35 36 * 38 * 39 * 40 * 41 * 42 * 43 * 44 51 52 53 54 55 56 57 59 62 65 * 66 * 67 * 68 * 69 * 70 * 71

6-1 Sequence Valve (hammer only) Flow Regulator Valve Anti-cavitation Check Valve 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

LOW FLOW OPTIONS

71 JJ

MM

Hammer

69 M

MM

M

68

67 11

EXTENDING DIPPER

MM

A325660

Issue 4*

Section E

Hydraulics

6-2

Section E

Schematics

6-2

3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines

35

C

1B 31 4 T

62

54

4G 6

33

4H

6B

6A

4A

40 S

4J

3 4B

39

3E

65

59 4K 4L

3F P2

41

3D

P1 3J

P1

P2

3B

15

2A 26 T

ACC

3Q

3J

43 3A

3M

4E

42

51

4F JJ

4P

JJ

T

7

53

8

10

32

12 36

57

59

44

3N

13

66

4M 4N

3L 16

55

4D

3C

52

4C

3G

34

56

38

11

14

P2A 9

1A M

5A

5B

M

5C

A262643

9803/3270

Issue 7

Section E

Hydraulics

Section E

Schematics

6-3

6-3

3CX ‘S’ Series & 4CX Gear Pump Options

3CX ‘S’ Series Options

This circuit shows the Extending Dipper and Power Sideshift, for the main hydraulic circuit see pages E/6-1 and E/6-2.

This circuit shows the Low Flow Hammer, Extending Dipper and Power Sideshift, for the main hydraulic circuit see pages E/6-1 and E/6-2.

Component Key

Component Key

HPCO

HPCO

M MM T 10 11 69 72 73 74 75 76

High Pressure Carry Over (From Excavator Valve Block 4) Hydraulic Connections 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

High Pressure Carry Over (From Excavator Valve 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

M MM T 11 69 72 73 74 76 77

69

69

77 11

75 11 10 HPCO 76

M

76

HPCO

72

72

74 T

74

M

T

73

M

A325670

73 A327030

9803/3270

Issue 1

Section E

Hydraulics Schematics

6-4

Section E 6-4

3CX ‘S’ Series Options This circuit shows the Low Flow Hammer and Extending Dipper, for the main hydraulic circuit see pages E/6-1 and E/6-2. Component Key HPCO M T 11 69 76 77

High Pressure Carry Over (From Excavator Valve Block 4) Hydraulic Connections Hydraulic Tank Return Sequence valve Extending Dipper Ram Isolation Valve Hammer

69

77 11

76

HPCO

T M M

9803/3270

A327040

Issue 1

Section E 6-5

Hydraulics

Section E

Schematics

6-5

Servo Command Pilot Circuit This circuit shows the pilot circuit for Servo Command machines. For main system hydraulics see the relevant schematics. Component Key E Engine P1 Pump, main section inlet P2 Pump, secondary section inlet PS Priority steer inlet T Tank 1 Seat 1A Right Hand Joystick Control Lever 1B Left Hand Joystick Control Lever 2 Auxiliary Valve Block 2A Auxiliary Spool 1 2B Auxiliary Spool 2 2C ARV 2D ARV 2E ARV 2F ARV 3 Loader Valve Block 3B Unloader Pilot Valve 3C Loader Lift Ram Spool 3D Loader Shovel Ram Spool 3E Clamshovel Spool 3F Shovel Ram Head Side A.R.V. 3G Shovel Ram Rod Side A.R.V. 3L Unloader Valve Spool 3M Main Relief Valve (MRV) 3N Unloader Check Valve 3Q Hydraulic Speed Control Solenoid 4 Excavator Valve Block Excavator services shown here are to the ISO control pattern. 4A Slew Spool 4B Dipper Spool (Boom SAE+) 4C Right Stabiliser Spool 4D Left Stabiliser Spool 4E Boom Spool (Dipper SAE+) 4F Bucket Spool 4G Hydraclamp Valve (Sideshift Only) 4H Slew A.R.V. 4J Slew A.R.V. 4K Dipper Ram Head Side A.R.V. 4L DipperRam Rod Side A.R.V. 4M Boom Ram Rod Side A.R.V. 4N Boom Ram Head Side A.R.V. 4P Bucket Ram Head Side A.R.V. 4Q Bucket Rod Side ARV (Hammer Only) 5 Manifold Block 5A Left/Right Hand Pilot Pressure Valve 5B Left Hand Pilot Pressure Valve 5C Arms/Boom Changeover Valve 5D Arms/Boom Changeover Valve 5E Shovel/Bucket Changeover Valve 5F Shovel/Bucket Changeover Valve 5G Pilot Filter (10 micron) 5H Pressure Reducing Valve (PRV) (preset 30bar) 6 Accumulator (5 bar precharge) 7 Steer Priority Valve 8 Test Points

9803/3270

9 10 11 12 13 14 26 31 32 33 34 35 36 44 51 52 53 54 55 56 57 62

Suction Strainer Tank Cap/Breather In line check valve (10 bar) Tank filter and by-pass valve Anti Cavitation Check Valve Last Chance Filter 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. Steer Control Valve Bucket Ram Boom Ram Stabiliser Ram Stabiliser Ram Dipper Ram Left Hand Slew Ram Right Hand Slew Ram Hydraclamps (Sideshift Only)

Issue 1

Section E

Hydraulics

6-6

Section E

Schematics

6-6

Servo Command Pilot Circuit 14

3 3E

35/36

62 4

3G 31/32

4G

3D

3F

44 7

33/34

3C

4A

44

11

5

4H 56/57

5H 3B

14

3L

3Q

5G

3N

4B

6 5A

4L

5B

T 1A 1

3

55

4C

8

54 4D

C1

P

4K

8

8

3M

14

4J

C2

4

5C

C4

4E

B1

2 C3

53

A1

5D

4M

A2 B2

5E

4N 4F

A3

4P

B3

1 5F

52

51

A4 B4

4Q

3 2

1B P

4

1

T

1A 1B

2 P

T

2A

13

2C

10 26 P1

P2

2B

E 1 A347590

9803/3270

2

3

4

2D 2E

12 9

T

2F A337211

Issue 2

Section E

Hydraulics

6-7

Section E

Schematics

6-7

3CXE (214E Series 3) Machines Only GG

F

NEUTRAL CIRCUIT H.P.C.O.

S

W

A H

EE SLEW

DD

B

2WS FRONT POWER TRACK ROD SHOVEL

BOOM

ENGINE

Y

Y

D Z

LOADER

L

STABILISER

R

BB

CC

N C

AA

STABILISER

MRV

Z

J

Y P

LS

T

DIPPER

LS EF

Q

P

CF

H

BUCKET

PP

EE

FF

H.P.C.O.

E W F

HAMMERMASTER 260L

HAMMERMASTER 280

HAMMERMASTER 360

L G NEUTRAL CIRCUIT / TANK RETURN

G

A262651

K HAMMER RETURN HAMMER FEED

Component Key A B C D E F G H J

Hydraulic Tank In-tank Filter Hydraulic Oil Cooler Single Stage Hydraulic Pump One Way Restrictor Shovel Rams Quick Release Couplings Lift Rams Loader Valve Block

9803/3270

K L N Q S W Y Z AA

Flow Regulator Valve Pressure Test Point Steer Valve Priority Valve Excavator Valve Block Stabiliser Rams One Way Restrictor Slew Rams Boom Ram

BB Dipper Ram CC Bucket Ram DD Suction Strainer EE Stabiliser Check Valve * FF Filter Fitted from machine serial number 475518 or see bulletin 2/218. Tank Cap * GG

Issue 1

Section E

Hydraulics

Section E

6-8

6-8

214e Series 4 Machines Only GG

P


S

F

W

A EE SLEW

DD

B

H

SHOVEL

2WS FRONT POWER TRACK ROD

J4

BOOM

F

ENGINE

Y

Y

D LOADER

Z

J3 L

STABILISER

R

BB

CC

N AUX

J2

AA

STABILISER

Z

C

Y P

LS

T

DIPPER

MRV

J1

J

LS EF

P

CF

Q

BUCKET

PP

H

EE

FF

H.P.C.O.

E W F HAMMERMASTER 260L

HAMMERMASTER 280

HAMMERMASTER 360

P B

L

A

NEUTRAL CIRCUIT / TANK RETURN

K

G

M

G

HAMMER RETURN HAMMER FEED

Component Key A B C D E F G H J J1

Hydraulic Tank In-tank Filter Hydraulic Oil Cooler Single Stage Hydraulic Pump Twin Check Valve Shovel Rams Quick Release Couplings Lift Rams Loader Valve Block Main Relief Valve

9803/3270

J2 Auxiliary Spool J3 Lift Spool J4 Shovel Spool K Flow Regulator Valve (Option) L Pressure Test Point M Auxiliary Valve Block (Option) * Either option K or M can be fitted but not both. N Steer Valve P Auxiliary Rams

Q S W Y Z AA BB CC DD EE

Priority Valve Excavator Valve Block Stabiliser Rams One Way Restrictor Slew Rams Boom Ram Dipper Ram Bucket Ram Suction Strainer Stabiliser Check Valve

* FF Filter Fitted from machine serial number 475518 or see bulletin 2/218. * GG Tank Cap

A313421

Issue 1

Section E

Hydraulics

Section E

6-9

6-9

214Se Series 4 Machines Only


GG

1

P S

F

W

2

A

EE

S1

DD

B

SLEW

H 4 J4

SHOVEL

S2

ENGINE

BOOM

R

L

Y

3

D J3

LOADER

Y Z

S3

STABILISER

BB N S4

J2

AUX

CC

HH

AA

STABILISER

Z

C

Y P

LS

T

S5

DIPPER

J4

BUCKET

MRV

J1

J

LS EF

P

CF

L

Q PP

H

EE

FF

H.P.C.O.

E W F

HAMMERMASTER 260L

HAMMERMASTER 280

HAMMERMASTER 360

P B

L

A

NEUTRAL CIRCUIT / TANK RETURN

G

M

K

G

HAMMER RETURN HAMMER FEED

Component Key A B C D E F G H J J1

Hydraulic Tank Return filter Hydraulic Oil Cooler Single Stage Hydraulic Pump Twin Check Valve Shovel Rams Quick Release Couplings Lift Rams Loader Valve Block Main Relief Valve

9803/3270

J2 Auxiliary Spool J3 Lift Spool J4 Shovel Spool K Flow Regulator Valve (Option) L Pressure Test Point M Auxiliary Valve Block (Option) Either option K or M can be fitted but not both. N Steer Valve P Auxiliary Rams

Q S S1 S2 S3 S4 S5 S6

Priority Valve Excavator Valve Block Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool

W Y Z AA BB CC DD EE

Stabiliser Rams One Way Restrictor Slew Rams Boom Ram Dipper Ram Bucket Ram Suction Strainer Stabiliser Check Valve

FF Last Chance Filter GG Tank Cap HH Extending Dipper 1 Front Power Track Rod 2 Rear Power Track Rod 3 Steer Control Valve 4 Steer Selector Valve Note: Smooth Ride Schematic, see page E/50-2 A356640

Issue 1

Section E

Hydraulics

7-1

Section E

Schematics Variable Flow Hydraulics

7-1

4CXE, 4CX Super Machines (7 Spool With High Flow Options)

49 T

7 P

LS

25

8 P

50

54

26 L

3

P

R

T

49

18

17 45

B 15

48

S 5

6

T

B

P

A

27

B 53

A 15A

46

4

51

LS

52

28

L

18

17

L1 47

16 29 P

B 36

T

A 16

43 28

T 17 P PRLS

LS

T

1 17

10 2

11

9

15

37

30

B A

15

PR

20

17 21

18

44

17

19

22

18

31

18 12

B A

B

17

38

18

A 32

17

19 18

15

B

17

16

17

19 18

21 20

P2

B A

ACC

17

14 P1

40 33

15 23

22

18

15

A T

39

A

13

24

B

B A

18

16

41 34

LS

B A

16A

A278942

9803/3270

Issue 4

Section E

Hydraulics Schematics Variable Flow Hydraulics

7-2

Section E 7-2

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). T 1 2 P 3 4 5 6 7 8 9 10 11 12 13 14 15 15A 16 16A 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Hydraulic Tank By-pass Filter Suction Line Pump Variable Flow Stroking Piston Control Piston System Pressure Spool Stand-by Pressure Spool Hydraclamp Valve Hydraclamps Loader Valve Block Priority Inlet Section Relief Valve † Auxiliary Service Spool Shovel Service Spool Lift Service Spool Auxiliary Relief Valves (anti-cavitation) ARV item 16 if Rockerbreaker Application Auxiliary Relief Valves (direct acting) ARV Only Fitted For Rockbreaker Application Secondary Shuttle Valve Primary Shuttle Valve Load Hold Check Valve Auxiliary Rams Shovel Rams Lift Rams Smooth Ride Selector Valve Smooth Ride Accumulator Backhoe Loader Valve Block Extradig Priority Valve Extradig Service Spool Compensator Valves Slew Service Spool Boom Service Spool Stabiliser Service Spool Stabiliser Service Spool Dipper Service Spool Bucket Service Spool Extradig Ram Slew Rams Boom Ram

9803/3270

38 39 40 41 42 43 44 45 46 47 48 * 49 * 50 * 51 * 52 * 53 * 54

Stabiliser Ram Stabiliser Ram Dipper Ram Bucket Ram Accumulator Oil Cooler Load Sense Relief Valve Steer Unit Assembly Steer Valve Relief Valve Shock Valves Quick release Couplings Isolation Valve Extending Dipper Isolation Valve Foot Valve Extending Dipper Ram Hammer

† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2 (173 bar, 176 kgf/cm2) this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.

Issue 3*

Section E

Hydraulics Schematics Variable Flow Hydraulics

7-3

Section E 7-3

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). T 1 2 P 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 24 25 28 29 30 31 32 33 34 36 37

Hydraulic Tank By-pass Filter Suction Line Pump Variable Flow Stroking Piston Control Piston System Pressure Spool Stand-by Pressure Spool Hydraclamp Valve Hydraclamps Loader Valve Block Priority Inlet Section Relief Valve † Auxiliary Service Spool Shovel Service Spool Lift Service Spool Auxiliary Relief Valves (anti-cavitation) Auxiliary Relief Valves (direct acting) ARV Only Fitted For Rockbreaker Application Secondary Shuttle Valve Primary Shuttle Valve Load Hold Check Valve Auxiliary Rams Shovel Rams Lift Rams Smooth Ride Selector Valve Smooth Ride Accumulator Backhoe Loader Valve Block Compensator Valves Slew Service Spool Boom Service Spool Stabiliser Service Spool Stabiliser Service Spool Dipper Service Spool Bucket Service Spool Slew Rams Boom Ram

9803/3270

38 39 40 41 42 43 44 45 46 47 48 49 50 54 55

Stabiliser Ram Stabiliser Ram Dipper Ram Bucket Ram Accumulator Oil Cooler Load Sense Relief Valve Steer Unit Assembly Steer Valve Relief Valve Shock Valves Quick release Couplings Isolation Valve Hammer Load Sense Isolation Valve

† Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2 (173 bar, 176 kgf/cm2) this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.

Issue 1

Section E

Section E

Hydraulics

7-4


7-4

4CXE, 4CX Super Machines (6 Spool With High Flow Options) 49 7

50 54

P

8 L

3

P

49

R

T

55

45

B 48

S 5

6

T

B

P

A

T

LS

P

46

4

25

LS

L

28

X

18

17

L1 47

16 29 P

B 36

T

A 16

43 28

T 17 P PRLS

LS

T

1 17

10 2

11

9

15

37

30

B A

15

PR

20

17 21

18

44

17

19

22

18

31

18 12

B A

B

17

38

18

A 32

17

19 18

15

B

17

16

17

19

17

14

21 20 A347590

9803/3270

P2

B A

ACC 18

P1

40 33

15 23

22

18

15

A T

39

A

13

24

B

B A

18

16

41 34

LS

B A

16A

A337210

Issue 1

Section E

Hydraulics

Section E


7-5

7-5

4CX, 4CX Super Machines Hand Held Tools Option X 1

2

3

LS

9

4

25 LS

LS

5

T P 6

A322650

Component Key P T X 1 2 3 4 5 6 9 25

Pump Variable Flow Hydraulic Tank Main Circuit Connection Pressure Flow Regulator High Pressure Flow Spool Relief Valve (2000 lb/in2 - 138 bar - 146 kgf/cm2) Load Sense Solenoid Hand Held Tool Shuttle Valve Excavator Valve Block Loader Valve Block

9803/3270

Issue 1

Section E

Hydraulics

Section E

Machine Neutral Circuit Description

8-1

8-1

3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines Oil is drawn from the hydraulic tank T by the hydraulic pump. The pump has two sections, P1 and P2. The hydraulic pump is driven by the engine 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 join flow from P1 at the loader valve.

To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the return line. The check 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 hose 62A is

fitted. The hose connects the hydraclamp spool directly into the exhaust circuit. This prevents the clamps from ‘lockingup’ when the sideshifting operation is required.

From the loader valve neutral gallery, oil flows via a high pressure carry-over line 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.

4 3

62A 13

7

62A

6

T

P2

9803/3270

P1

26 S262661

Issue 2*

Section E

Hydraulics

Section E

Machine Neutral Circuit Description

9-1

9-1

3CXE (214E) Machines Oil is drawn from the hydraulic tank T by the single stage hydraulic pump P. The pump is mounted on the chassis 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.

To help prevent excavator dipper ram and loader lift ram cavitation, there is a check valve 13 fitted to the return line. The check valve raises approximately 5 bar (75 lbf/in 2) of pressure in the line, which improves the operation of the respective anti-cavitation valves.

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.

1B 4

3 7 13

6

T

26

P

9803/3270

S262670

Issue 1

Section E

Hydraulics

Section E

Machine Neutral Circuit Description Servo Command

9-2

9-2

Servo Pilot Circuit The servo command hydraulic neutral circuit is as described by machine series type. Servo command differs in that the spools are moved by pilot pressure and not mechanical lever. Spools movement is controlled by a joystick control lever or an electrical switch. Pilot pressure is generated by tapping into the steer neutral circuit at the steer priority valve 7, the oil is directed to the manifold block 5. The pressure reducing valve 5H provides a pilot circuit of 30 bar (435 lbf in2). The manifold block houses a pilot filter to protect the circuit and solenoid valves which direct pilot pressure to the various controls.

Solenoid 5A provides pilot pressure to the right hand joystick control lever 1A, loader and backhoe valve block electrical selections. Solenoid 5B provides pilot pressure to the left hand joystick contol lever 1B. Solenoids 5C to 5F are changeover solenoids and operate when the seat is rotated or when the mode changeover switch is operated. In the event of engine failure or hydraulic pump failure the accumulator 6 provides sufficient pilot pressure to allow several operations in order to make the machine safe ie. lower machine to ground or lower loader arms and boom/dipper.

1B

1A

2

4

3

6 AB 5H

7 C D

E

F

5

9803/3270

351980

Issue 1

Section E

Hydraulics

Section E

Machine Neutral Circuit Description Variable Flow Hydraulics

9 - 10

9 - 10

4CX, 4CX Super Machines The variable flow displacement pump P is mounted on the chassis 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 demand signal from the services (see pump operation). If there is no demand, then the pump does not draw oil from the tank 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 backhoe 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 loader valve 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 the return line. The check valve raises approximately 5 bar (75 lbf/in 2) of pressure in the line, which improves the operation of the respective anti-cavitation valves.

4

26

3

1A

13 6

T P

9803/3270

S271361

Issue 2

Section E

Hydraulics

Section E

Hydraulic Pumps

10 - 1

A

A

10 - 1

B

B

C D

S266240

9803/3270

Issue 1

Section E

Hydraulics

Section E

Hydraulic Pumps

10 - 2

10 - 2

Pump Description The basic principle of the gear pump depends on the meshing of two spur gears E, one of which is engine - driven while the other is an idler.

E

Oil is picked up by the gear teeth on the suction side of the pump and carried around between 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 through the pump outlet.

Pump Flow 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 (JCB Part No. 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

S262680

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/in2) 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.

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

*3

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. TRANS 1-2

4

5

9803/3270

Start the engine and bring the hydraulics up to working temperature 50ºC (122ºF). Set the engine speed to 2200 rpm. 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 note its reading at the moment the MRV operates.

The flow reading should be as listed in Technical Data.

Issue 2*

Section E

Hydraulics

Section E

Hydraulic Pumps

10 - 3

10 - 3

Removal and Replacement Procedures describe removal and replacement of a double section pump, follow same procedures for single section pumps (as fitted to 3CXE (214E) machines). Removal

Replacement


Replacement is generally a reversal of the removal procedure. Renew all O-rings.

GEN 3-2

Attach the pump to the flange mounting face using bolts D. Raise the loader arms and fit the loader arm safety strut. If hydraulic pressure is not available, select 'lift arms raise' on control lever whilst lifting arms with a suitable hoist. Release screws A and remove the front radiator grille B. Drain the hydraulic fluid. Disconnect the pump inlet and outlet hoses X and Y respectively.

! 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.

Connect inlet hose X and outlet hoses Y. Fill the system to the correct level with recommended hydraulic fluid, see page 3/1-2. 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. Refit the radiator grille B and secure in position with screws A.

HYD 2-3

Secure the pump using a sling, remove the pump mounting bolts D and lift the pump clear of the machine.

Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter.

B Y

Y D X

A

S266260

9803/3270

Issue 1

Section E

Hydraulics

Section E

Hydraulic Pumps

10 - 3A

10 - 3A

Removal and Replacement Procedure describes removal and replacement of a single section pump, engine mounted as fitted to 214Se machine.

Replacement

Removal

Replacement is generally a reversal of the removal procedure.


Renew all O-rings and gaskets. Apply Threadlocker and Sealer to bolts C. Attach the pump to the flange mounting face using bolts C.

GEN 3-2

Connect inlet hose A and outlet hose B. Raise the loader arms and fit the loader arm safety strut. If hydraulic pressure is not available, select 'lift arms raise' on control lever whilst lifting arms with a suitable hoist. Disconnect the battery.

Replace suction strainer and return line filter after fitting a new or serviced pump. Fill the system to the correct level with recommended hydraulic fluid, see page 3/1-5.

Open the left hand side engine panel.

! 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

Drain the hydraulic fluid. Disconnect the pump inlet A and outlet hose B.

After fitting a new or serviced pump and before starting the engine screw the main relief valve (M.R.V) out. Run the engine and check for leaks, also check the main relief valve (M.R.V.) operating pressure. Torque Settings Item B C

Nm 84 28

kgf m 8.5 2.8

lbf ft 62 20.6

Disconnect the transmission dipstick bracket and the engine oil dipstick tube.

* Undo bolts and remove support bracket D. Undo bolts C, remove pump from the machine.

C

Note: The two outer bolts are flange bolts and the three inner bolts are cap screws which require a 8 mm extended Allen key fitted to a drive socket.

A

D

B A359380

9803/3270

Issue 2*

Section E 10 - 4

Hydraulics

Section E

Hydraulic Pumps

10 - 4

S193110

9803/3270

Issue 1

Section E 10 - 5

Hydraulics

Section E

Hydraulic Pumps

10 - 5

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 key 1 and circlip 2. 2

Remove the four bolts 3 and serrated washers 4 which clamp the units together.

3

Use a soft faced hammer to separate front body 5 and rear body 6 after first marking them to ensure correct re-assembly.

4

Remove splined coupling 7 and O-rings 8. Discard the O-rings.

5

Use a soft faced hammer to separate end cover 9 from rear body 6, after first marking them to ensure correct re-assembly.

6

Remove drive gear 10 from its bore. Pushing it out of the rear body will also remove balance plate 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.

7

Remove driven gear 14, followed by balance plate 15 complete with seal 16 and seal energiser 17. Discard the seal and seal energiser.

8

Discard O-ring 18.

9

Use a soft hammer to separate mounting flange 19 from front body 5, after first marking them to ensure correct re-assembly.

10

Remove circlip 21 and shaft seal 22.

11

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.

12

Remove driven gear 27 followed by balance plate 24, seal 25 and seal energiser 26. Discard the seal and seal energiser.

9803/3270

13

Discard O-ring 31.

14

Remove all sealant from the contact faces of the mounting flange/front body and end cover/rear body interfaces.

15

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 mounting flange and the end cover are worn through to reveal the bronze backing.

b

The gear side faces are scored. Often 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 seal 22 runs.

d

The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

e

The parallel diameter/keyway 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.

Issue 1

Section E 10 - 6

Hydraulics

Section E

Hydraulic Pumps

10 - 6

S193110

9803/3270

Issue 1

Section E 10 - 7

Hydraulics Hydraulic Pumps

Section E 10 - 7

Dismantling and Assembly (continued) Assembling 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

Note: If the seal recess is scored, it is permissible to seal outside diameter with Loctite hydraulic sealant to prevent leakage.

Apply a small amount of Loctite sealant to the 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.

2

Stand front body 5 on its rear face. Fit seal 25 and seal energiser 26 into balance plate 24.

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).

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).

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.

When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. 1

Fit shaft seal 22 into mounting flange 19 with its garter spring facing into the pump. Fit circlip 21 into its groove in the flange. Coat the seal lips with high melting point grease.

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 Loctite sealant 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.

9803/3270

Issue 1

Section E 10 - 8

Hydraulics

Section E

Hydraulic Pumps

10 - 8

* Dismantling and Assembly - 3CXE (214E & 214e) Machines- Model No. 6197C 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.

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 body and mounting flange are worn through to reveal the bronze backing.

b

The gear side faces are scored. Often 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 (6) where seal (9) runs.

d

The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

e

The parallel diameter/keyway 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.

Dismantling 1

Remove key (14) and circlip (15).

2

Mark body (1) and flange (8) to ensure correct reassembly.

3

Remove 4 nuts (11) and washers (12), separate flange and body using a soft faced hammer.

4

Remove retaining circlip (10) and inner shaft seal (9) from flange ensuring that shaft seal recess is not damaged.

5

Grasp driveshaft (6) and remove with balance plate (18), complete with seal (17) and seal energiser (16). Note position of these for correct re-assembly.

6

Remove driven gear (5) followed by balance plate (4), seal (3) and seal energiser (2). Note position of these for correct re-assembly.

7

Remove and discard all seals and clean off all sealant from the flange/body interface.

S248410

9803/3270

Issue 2*

Section E 10 - 9

Hydraulics

Section E

Hydraulic Pumps

10 - 9

* Dismantling and Assembly - 3CXE (214E & 214e) Machines- Model No. 6197C Assembling When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. To prevent damage to pump seals, after fitting a new or serviced pump and before starting the engine screw the MRV out. Reset the MRV as described in Pressure Testing. 1

Stand front body (1) on its rear face. Fit seal (3) and seal energiser (2) into balance plate (4).

2

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of the front body (1) 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).

3

Insert driveshaft (6) and driven gear (5) into the original bores.

4

Fit balance plate (18) over the driveshaft and gear stub. Insert seal (17) and seal energiser (16) into the balance plate.

5

Fit O-ring (7) into the groove on mounting flange (8).

6

Apply a small amount of Loctite sealant to the face of front body (1) which seals with mounting flange (8) (i.e. the face containing the clamping bolt holes). Sealant is applied outboard of oval location and is used to prevent moisture entering - it is NOT an hydraulic seal.

7

Carefully feed mounting flange (8) over driveshaft (6) in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot.

8

Fit washers (12) and nuts (11) to studs and torque tighten.

9

Fit protective sleeve (included in seal kit) over the drive shaft, carefully feed shaft seal (9) over shaft with garter spring facing into pump and push down into flange recess using a suitable tool, fit circlip (10), carefully remove protective sleeve.

10

Pour a small amount of clean JCB Special Hydraulic Fluid into the ports. Check that driveshaft (6) 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.

Torque Settings Item 11

Nm 95 ± 5

kgf m 9.7 ± 0.5

lbf ft 70 ± 4

S248410

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Hydraulic Pumps

10 - 10

Dismantling and Assembly - 3CXE (214E & 214e) Machines- Model No. J101702

10 - 10

Assembling

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 The numerical sequence shown on the illustration is intended as a guide to dismantling. Remove sharp edges and burrs from the shaft to avoid seal damage. Mark cover 1 and housings 2 to ensure correct replacement Use a soft-faced hammer to separate components. Do not use levers, or machined surfaces may be damaged. Mark adjacent teeth of gears 11 with indelible ink before removal. Do not use a centre punch or similar tool. Inspection All pumps have a 'gear track' in the suction side of the housing, which is cut by the gears during initial testing by the manufacturer. This is not detrimental unless bearing wear or dirt has caused the track to be worn deeper than 0.1mm (0.004 in).

When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. To prevent damage to pump seals, after fitting a new or serviced pump and before starting the engine screw the MRV out. Reset the MRV as described in Pressure Testing. Seals 6, 9 and back-ups 7, 10 must be fitted as follows, using JCB 'MPL' Grease to retain them in the grooves: First fit the seal into the wear plate 5 and 8 with the flat side facing downwards. Then fit the back-up on top of the seal with the shoulder at each end of the back-up facing downwards to seat on the base of the groove. Fit wear plates 5 and 8 with recesses A facing the gears and the seal and back-up towards the pressure side of the pump. Ensure that seal and back-up are not trapped between the plate and the bore. Check also that wear plates 5 and 8 are fully home in the bore and free to move. Insert the shaft seal 13 into the end cover 1 make sure the seal is square and is pushed fully in. To check the shaft seal is seated correctly measure B which should be 17.27 to 17.78 mm (0.68 to 0.70 in). Align gears 11, housing 2 and cover 1 using the marks made when dismantling. Torque Settings Item 1

Nm 170

kgf m 17.3

lbf ft 125

The seals and wear plates are the only serviceable items, if the gears, bearings, housing or cover are damaged fit a new pump.

B

2 12 3

10

9 8

11

A

5

6 7

1

11 13

4

327740

9803/3270

Issue 1

Section E

Hydraulics

Section E

Hydraulic Pumps

10 - 11

Dismantling and Assembly - 214Se Machines - Model No. J101701

10 - 11

To prevent damage to pump seals, after fitting a new or serviced pump and before starting the engine screw the MRV out. Reset the MRV as described in Pressure Testing.

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.

Seals 6, 9 and back-ups 7, 10 must be fitted as follows, using JCB 'MPL' Grease to retain them in the grooves: First fit the seal into the wear plate 5 and 8 with the flat side facing downwards. Then fit the back-up on top of the seal with the shoulder at each end of the back-up facing downwards to seat on the base of the groove.

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.

Fit wear plates 5 and 8 with recesses A facing the gears and the seal and back-up towards the pressure side of the pump. Ensure that seal and back-up are not trapped between the plate and the bore. Check also that wear plates 5 and 8 are fully home in the bore and free to move.

Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling. Remove sharp edges and burrs from the shaft to avoid seal damage.

Insert the shaft seal 13 into the end cover 1 make sure the seal is square and is pushed fully in. To check the shaft seal is seated correctly measure B which should be 17.27 to 17.78 mm (0.68 to 0.70 in).

Mark cover 1 and housings 2 to ensure correct replacement. Use a soft-faced hammer to separate components. Do not use levers, or machined surfaces may be damaged.

Align gears 11, housing 2 and cover 1 using the marks made when dismantling.

Mark adjacent teeth of gears 11 with indelible ink before removal. Do not use a centre punch or similar tool.

Use a new tab washer 15 and key 4, fit drive gear 14 nut 16, bend tab 15 to lock nut 16.

Bend tab 15 to unlock nut 16. Undo nut 16 and remove drive gear 14.

Torque Settings Item Nm kgf m 3 170 17.3

Inspection

lbf ft 125

All pumps have a 'gear track' in the suction side of the housing, which is cut by the gears during initial testing by the manufacturer. This is not detrimental unless bearing wear or dirt has caused the track to be worn deeper than 0.1mm (0.004 in).

3

The seals and wear plates are the only serviceable items, if the gears, bearings, housing or cover are damaged fit a new pump.

2 12

Assembling

10 9

When carrying out the following procedure, renew all seals, gaskets and O-rings. Lubricate using JCB Special Hydraulic Fluid.

8 11

B

4 5 6 7 13 14 1 9803/3270

15 16 17

S342522

Issue 1

Section E

Hydraulics

Section E

Hydraulic Pumps Variable Flow Hydraulics

10 - 20

10 - 20

Pump 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 required, only sufficient fluid for cooling 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 the pump exterior is the valve block 9 housing the 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.

ITEM P 1 2 3 4 5 6 7 8 9

DESCRIPTION Pump Cylinder Barrel Drive Shaft Kidney Plate Axial Piston Swashplate Shoe Plate Stroking Piston Control Piston Pressure/Flow Compensator Valve

9

P

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.

271430

7

1

3

5

2

6 9803/3270

4

8

S271440

Issue 1

Section E

Hydraulics

Section E


10 - 21

10 - 21

Neutral Circuit Pressure Pressure Generated by Operation of a Service Trapped Oil Exhaust

13

P

LS

1 2

5 12 11 6

10

T

4

9 A P 3 8

7

A275730

9803/3270

Issue 1

Section E 10 - 22

Hydraulics

Section E


10 - 22

Pump Pressure/Flow Regulator Valve Operation 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.

5

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 .

4 3 P

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.

2

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.

9803/3270

T

7

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 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 moves back to partially cover the cross holes thus maintaining enough flow to cater for normal system leakage whilst establishing a system stand-by pressure (see Technical Data for pressure).

A

1

A275760

Issue 1

Section E

Hydraulics

Section E


10 - 23

10 - 23


13

P

LS

1 2

5 12 11 6

10

T

4

9 A P 3 8

7

A275740

9803/3270

Issue 1

Section E 10 - 24

Hydraulics

Section E


10 - 24

Pump Pressure/Flow Regulator Valve Operation Load Sensing - Maximum Flow

5

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.

6 4 3 P

The pump output pressure will continue to increase, 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 equivalent to 20 bar (290 lbf/in 2 ), therefore the pump pressure should be this amount greater than the signal pressure (except when at maximum pressure - see description ‘maximum pressure (no flow)’.

A

T

7 2

1

A275770

9803/3270

Issue 1

Section E

Hydraulics

Section E


10 - 25

10 - 25


13

P

LS

1 2

5 12 11 6

10

T

4

9 A P 3 8

7

A275750

9803/3270

Issue 1

Section E 10 - 26

Hydraulics

Section E


10 - 26

Pump Pressure/Flow Regulator Valve Operation Load Sensing - Maximum Pressure (no flow)

5

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.

6

4

12 3 P

Control piston 7 moves thus decreasing the 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.

A

T

7 2

1

A275780

9803/3270

Issue 1

Section E

Hydraulics

Section E


10 - 27

10 - 27

Pump Removal and Replacement

Replacement

Removal

Replacement is generally a reversal of the removal procedure.

! WARNING

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

Renew all O-rings. Inspect the anti-vibration collar E for signs of damage, the collar must be a good tight fit in the chassis.

GEN 3-2

Raise the loader arms and fit the loader arm safety strut. If hydraulic pressure is not available, select 'lift arms raise' on control lever whilst lifting arms with a suitable hoist. Remove the front radiator grille. Drain the hydraulic fluid. Disconnect the pump inlet and outlet pipe flanges A and B respectively. Discard the ‘O’ rings C.

! CAUTION The 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.

Inspect the resilient mounts F for signs of damage and deterioration, replace with new ones as required. Connect pipes A and B. Torque tighten pump driveshaft capscrews (not shown) to 39 Nm; 3.9 kgf m; 29 lbf ft. Fill the system to the correct level with recommended hydraulic fluid, see page 3/1-2. IT IS EXTREMELY IMPORTANT THAT THE PUMP IS PRIMED PRIOR TO STARTING THE ENGINE. FAILURE TO PRIME THE PUMP WILL RESULT IN IRREPARABLE DAMAGE TO THE PUMP.

HYD 2-3/1

Secure the pump using a sling, remove the pump mounting nuts D. Pull the pump clear of the anti-vibration collar E, release the pump driveshaft locking screws (not shown) and lift the pump clear of the machine.

Prime the pump; remove case drain cap G and add 0.5 litres; 0.11 gal. Refit the cap.

B E

G C F

C

A F

D D

9803/3270

S273090

Issue 2

Section E

Hydraulics Hydraulic Pumps Variable Flow Hydraulics

10 - 28

Section E 10 - 28

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

9803/3270

Issue 1

Section E

Hydraulics

Section E


10 - 29

10 - 29

Pump Dismantling and Assembly

16 C

11 15 13 4

14

5 18

10

8

S272610

9 17

3

7 6 12 A

B 18

S272640

9803/3270

S213160

2

1 Issue 1

Section E 10 - 30

Hydraulics

Section E


10 - 30

Pump Dismantling and Assembly

Inspecting Parts

Before removing and dismantling the pump, make sure it is the pump that is at fault. Complete all the necessary checks as detailed in this section. Make sure that the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination. Following removal of the pump from the machine, transfer it to a clean dirt free environment ready for dismantling.

Generally check all pump parts for damage and/or wear. Any parts that are scored or damaged must be replaced with new ones.

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 Renewing Drive Shaft Seal on page E/10-28. 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.

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

6

Remove and discard port plate to pump housing ‘O’ ring 13.

Total

7

Remove bearing shells 14 and disc 17.

Known shim thickness Subtract calculated preload

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.

SHIM THICKNESS

9

Lift the valve plate 6 off the port plate, do not lose the dowel pins (not shown).

10

Remove and discard ‘O’ rings 18.

11

Remove control piston 7. Note that the control piston is mounted on the same side as the regulator valve.

12

Remove the stroking piston assembly 8.

Further dismantling and assembly of the pump is not recommended.

1.26 - 0.05 1.21 1.50 -1.21 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 tool. The shim (and the calculated shim) can be manufactured locally. Maintain a tolerance of ± 0.01mm (0.0004in.). The lubrication bore relief (item C) on the cradle must be fitted on the pressure side of the pump. Check the control piston and the stroking piston move smoothly. The regulator valve assembly is currently a non serviceable part.

9803/3270

Issue 1

Section E

Hydraulics

Section E


10 - 31

10 - 31

Pump Flow and Pressure Testing

D

* Machines from Serial Number 460001 to 472554 Without Relief Valve Only

C A B

S273361

D

* Machines from Serial Number 460001 to 472554 With Relief Valve and all from 472555

C

A

B

S315770

9803/3270

Issue 2*

Section E

Hydraulics

Section E


10 - 32

10 - 32

Pump Flow and Pressure Testing Load Sensing Pressure

Stand-by 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 effect on the hydraulic system. To check load sense 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

1

Warm the hydraulic oil to working temperature, i.e. 50°C (122°F):

1.1 Set the engine speed to 2200 rev/min. 1.2 Operate the loader shovel dump service to blow off the auxiliary relief valve.

1.1 Set the engine speed to 2200 rev/min. 1.2 Operate the loader shovel dump service to blow off the auxiliary relief valve. 2

3


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/in2) pressure gauge to pressure test connector B located on the pump pressure out line.

Connect a 0 - 400 bar (0 - 6000 lbf/in2) 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.

4


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.

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.

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

Refer to Regulator Valve Adjustment.

* 8

Machines up to 472554 with the load sense pressure relief valve and all machines from 472555 adjust the load sense pressure relief valve E. Machines up to 472554 without a load sense pressure relief valve adjust the regulator valve.

E

S315770

9803/3270

Issue 2*

Section E

Hydraulics

Section E


10 - 33

10 - 33

Pump Flow and Pressure Testing Maximum Hydraulic Stall 3


4


Machines from 460001 to 472554 with a load sense relief valve and on all machine from 472555, disconnect and blank the load sense relief valve E at F.

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.

1

6

If the pressure is higher than specified, the pressure compensator spool may be set incorrectly or the swashplate may not be moving.

With variable flow hydraulics 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 check the setting:

* Note:

Warm the hydraulic oil to working temperature, i.e. 50°C (122°F): 1.1 Set the engine speed to 2200 rev/min.

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.

1.2 Operate the loader shovel dump service to blow off the auxiliary relief valve. 2


Do not make any adjustments at this stage. Complete the other checks detailed in this section. 8


D

C

B

E

F

S315770

9803/3270

Issue 2

Section E 10 - 34

Hydraulics

Section E


10 - 34

Pump Flow and Pressure Testing Pump Flow

Load Sense Line 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).

The load sense line communicates the load pressure required at a service to the pump. If there is a blockage or leak in the line, the hydraulic system will not operate effectively.

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


Load sensing is a ‘dynamic flow’ type. That is, there is a constant flow of oil from the pump to the shuttle valves (see loader valve descriptions). 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). Refer to fig on page page E/10-31. 1


1.1 Set the engine speed to 2200 rev/min. 1.1 Set the engine speed to 2200 rev/min. 1.2 Operate the loader shovel dump service to blow off the auxiliary relief valve. 2

3

4

1.2 Operate the loader shovel dump service to blow off the auxiliary relief valve.


2



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.

Connect a flowmeter to the pump pressure out line as shown at C.

5


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 check the flow and pressure gauge 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


9803/3270

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.

Issue 2

Section E

Hydraulics

Section E


10 - 35

10 - 35

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

Pressure Regulator Spool

The pressure in the pump out line (pressure test connector B) should be 20 bar (290 lbf/in2) greater than the pressure in the load sense line (pressure test connector A). If not adjust the regulator flow spool as described below:

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


2

Remove the front grille to 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

Repeat pressure test as detailed previously and establish valve is set correctly.

6

Tighten locknut, refit cap and front grille.

1


2

Remove the front grille to 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

Repeat pressure test as detailed previously and establish valve is set correctly.

6

Tighten locknut, refit cap and front grille.

F

C G

H

D E

A

B

S273401

S273100

9803/3270

Issue 2

Section E

Hydraulics Hydraulic Pumps Variable Flow Hydraulics

10 - 36

Section E 10 - 36

Flow Regulator Valve On variflow machines the load sense system is a dynamic type, which means a small flow (0.22 to 1.1 gall/1 to 5 litre per minute) 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 services may operate intermittently even though the excavator operates correctly. If any of the above symptoms are experienced carry out the following service procedure. SERVICE PROCEDURE 1

Lower the backhoe bucket and loader shovel to rest on the ground. Stop the engine and remove the starter key.

2

Remove the front grille to gain access to the regulator valve assembly.

3

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.

4

Start the engine and measure the flow which should be at least 0.22 gall/1 litre per minute at 2200 RPM.

5

If the flow is below 0.22gall/1 litre per minute, remove spool B and clean/unblock orifice C as required.

6

Fit spool B and check the flow as described at step 3 and 4.

7

If the flow is within limits check the stand-by pressure as detailed on page E/10-32.

B B

C

A S347850

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 1

Loader Valve

11 - 1

* Loader

Valve Manual Description

The loader valve is mounted on the chassis frame, right hand side (when viewed from rear). Standard equipment includes loader lift spool (3C), shovel spool (3D) and unloader valve assembly (3L). Auxiliary spool (3E) is optional. Linkage rods connect the spool ends to the control levers.

Note: Refer also to Technical Data pages for port identifications.

Operation In neutral circuit hydraulic oil from pump section P2 enters the loader valve via a steering priority valve. On entering the valve block, oil flows around the waisted section of the unloader valve 3L, past a check valve and joins flow from pump P1.

B

Oil from pump section P1 enters the loader valve as shown. Combined oil flow from P1 and P2 passes the main relief valve (M.R.V. - not shown) 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.

A263040

3C

3D

3E

The exhaust gallery T is connected to the tank return line.

T Component Key 3 3C 3D 3E 3L 3M

Loader valve block Lift Ram Spool Shovel Ram Spool Clam Shovel Spool Unloader Valve Spool Unloader Pilot Valve

3M

3L P2

3

P1

1B

B T A262690

9803/3270

Issue 2*

Section E

Hydraulics

Section E

11 - 1A

Loader Valve

11 - 1A

Loader Valve Servo Description The servo loader valve is similar to the manual loader valve except the spools are operated by pilot pressure and not linkage rods, see Servo Pilot Circuit description on page E/92. Operation Same as manual loader valve. Component Key 3 3C 3D 3E 3L 3M

Loader Valve Block Lift Ram Spool Shovel Ram Spool Clam Shovel Spool Unloader Valve Spool Unloader Pilot Valve

3C

3D

3E

3M 3L

3

A337860

9803/3270

Issue 2

Section E

Hydraulics

Section E

11 - 2

Loader Valve

11 - 2

* Loader

Valve Manual


! 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 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

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 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 sealant (Loctite 577) applied to the threads of the adapter.

A

Loosen and remove nuts B, the loader valve and spacing washers C.

C B S266260

9803/3270

Issue 2*

Section E

Hydraulics

Section E

11 - 2A

Loader Valve

11 - 2A

A

A

H

G

F

H B

K

J

C

F

G

E D

F

9803/3270

G

351850

Issue 1

Section E

Hydraulics

Section E

11 - 2B

Loader Valve

11 - 2B

Loader Valve Servo Removal and Replacement



Removal




The illustration is viewed from the top when disconnecting pilot hoses and solenoid valves also disconnect the pilot hoses and solenoid on the bottom. 1

Operate the valve block joystick levers back and forth to vent accumulator pressure.

2

Disconnect all hydraulic pilot hoses A from the valve block and plug all orifices to prevent ingress of dirt. The hoses should be labelled, if not label each hose before disconnecting, this will ensure correct position when refitting.

3

Disconnect electrical connections B to auxiliary spool.

4

Disconnect hydraulic hoses to services C, inlet D, tank returns E and high pressure carry over J from the valve block, plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

5

Steer hose K is clipped to the valve block and may need disconnecting for access.

6

Loosen and remove nuts F, remove the loader valve assembly and spacing washers G.

7

If the pilot hose adaptors H are going to be removed, label before removing as restrictors are fitted in most positions.

9803/3270

Issue 1

Section E

Hydraulics

11 - 3

Loader Valve

Main Relief Valve (M.R.V.) Operation 1

Valve at Rest

The main relief valve (M.R.V.) 3B, situated in the loader valve block, provides control of both loader and excavator pressures. When a service is selected, pressure rises in the service line and back through the loader valve to the pump. The service is operating under light load and the pressure 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 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 (via cavity K and down the sides of sleeve J). Unless the pressure continues to rise, plunger A will remain on its seat. 3

Valve Moves off its Seat

When pump pressure rises to the setting of the main relief valve, 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 lower 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 into the exhaust gallery.

Section E

;;;;; ;; ;;; ;;;;; ;; ;;;;; ;; ;; ;; ; ;;;; ; ;; ;; ; ;;;; ;; ; ; ;;;;; ;; ; ;; ;; ;;; ;; ;; ; ;; ;; ;;;;;; ;; ; ;; ;; ;; ;; ;;

11 - 3

3B

G

F

K J

C D

A

H

E

B

A262700

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.

9803/3270

Issue 2

Section E

Hydraulics

Section E

11 - 4

Loader Valve

11 - 4

S262710

11 10

2

9

1 8

7 13 6 4

14

5

12

3

S262720

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 5

Loader Valve

11 - 5

Main Relief Valve Dismantling and Assembly

When Assembling

The numerical sequence shown on the illustration is intended as a guide to dismantling.

Renew all 'O' rings and back-up rings.

For assembly the sequence should be reversed.

Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.

The following points MUST be avoided when dismantling and assembling the valve:

Make sure that the 'O' rings and back-up rings are fitted the correct way, items 10 and 11.

• • •

Adjust pressure setting as required.

CONTAMINATION DAMAGE TO SPOOL DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.


Nm 5.4

kgf m 0.6

lbf ft 4

When 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.

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 6

Loader Valve

11 - 6

Auxiliary Relief Valve - FIG 1 A.R.V's are positioned in the excavator valve block in order to relieve excessive pressure in the services. 1

Valve at Rest

Figure 1 shows the service in neutral with no forces acting on the equipment.

E

The force of spring D acting through collar C keeps poppet B firmly held on its seat.

J

Chamber J is connected to the exhaust gallery via small drilled holes H, this means the pressure in the chamber will always be at exhaust. The A.R.V. pressure setting is adjustable by means of spring D and adjusting screw E. Turning the screw clockwise compresses the spring and therefore increases the pressure setting. And conversely, turning the screw anti-clockwise releases the spring which decreases the pressure setting. 2

H D

C

Poppet Opens

If the pressure in the service gallery A has reached the setting of the A.R.V., the pressure on the service side of the poppet is high enough to overcome the force of spring D so poppet B lifts off its seat. Oil in chamber J is displaced through small drilled holes H.

K

B A

Service pressure at A is now released into exhaust gallery K.

A262730

FIG 1

Load Hold Check Valves - FIG 2 The following text describes how the load hold check valve works in the arms raise service.

D

Operation 1 The weight of the loaded shovel 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

3J

As the neutral circuit has been blocked by the central land of the selected spool, the pressure in parallel gallery B increases until it is greater than that in service line D.

B 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

9803/3270

FIG 2 Issue 1

Section E

Hydraulics

Section E

11 - 7

Loader Valve

11 - 7

1 18 2 3 4

17 16 15

5 6 8 9 11

10

14

B

A

13 12

7

S197420

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 8

Loader Valve

11 - 8

Auxiliary Relief Valves (ARV) and Load Hold Check Valves (LHCV) Dismantling and Assembly

When Assembling






Fit back-up ring 13 on the upper side of 'O' ring 12.

• • •

Fit flat face of sleeve 9 against shoulder of poppet 10. 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 (see Technical Data). The LHCV's are identical. When Dismantling When removing 'O' rings and seals, use an an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

Torque tighten item 14 using the special tool (see Service Tools, Section 1), until its shoulder seats firmly against item 1. Pressure test the relief valves using the procedure described on page E/13-5. Torque Settings Item 1 3 15

Nm 65 24 81

kgf m 6.6 2.5 8.3

lbf ft 48 18 60

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, Section 1). 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.

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 9

Loader Valve

11 - 9

Unloader Valve Assembly 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 pump section P2 to tank, allowing engine power to be applied fully to the main pump section P1.

Because the unloader chamber is now connected to tank, and so at exhaust pressure, pressure in gallery C 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.

The unloader is operated automatically when the system pressure reaches 207bar (3000 lbs/in2). The unloader can also be operated manually, this is referred to as Hydraulic Speed Control (HSC), the main applications for manual operation are: 1 2 3

P1

More tractive force is made available to the loader end when entering a stockpile. More power from the engine is made available whilst travelling on the highway, giving improved fuel economy. Reduced backhoe speed when placing objects.

T 3B 3Q

System Operation Pressure in the inlet gallery C is sensed by pilot valve 3M via the bore of spool 3L. At pressure below the setting of the unloader valve, both pilot valve 3M and spool 3L remain closed.

1A 3N 3M 3L

P2

If the pressure in the inlet gallery C rises to the setting of 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.

A262810

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.

3Q

Oil entering the valve block from pump P2 now flows directly to tank (T). High pressure in gallery C also holds check valve 3N firmly closed, preventing oil from pump P1 from also being dumped. When pressure in the 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 P2 connection to tank.

3M 3P T 3L D C

Hydraulic Speed Control (HSC) Solenoid 3Q is connected between the unloader valve chamber 3P and the return to tank circuit. When the solenoid is de-energised spring force acting on the end of the spool keeps the connection from chamber 3P to tank closed. When the solenoid is energised, the spool moves causing a connection from the unloader spool chamber 3P to the hydraulic tank via valve block internal galleries and service hoses. 9803/3270

A262760

Issue 1

Section E

Hydraulics

Section E

11 - 10

Loader Valve

11 - 10

3 4

23

15

7 6 5

25

19 20 24 26

16

2

1

18 17 21 22

27

11 10 9 8

14

13

12

S197430

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 11

Loader Valve

11 - 11

Unloader Valve Assembly Dismantling and Assembly 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:

• • •


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. Ensure that the small drilling through the centre of items 23, is clear.

When Dismantling

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.

When removing 'O' rings and seals, use an an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

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).

Discard ALL 'O' rings and back up rings. DO NOT use worn or damaged items.

Fit chamfered end of spring 22 against head of pilot poppet item 23.

Use a nylon rod to push out spool assembly item 23, DO NOT damage spool bore.

Check pressure setting after refitting, see page E/13-2.


Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required.

Check the operation of the hydraulic speed control, see page E/13-2. Torque Settings Item 1 5 8 12 16 19

9803/3270

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

Issue 1

Section E

Hydraulics

Section E

11 - 12

Loader Valve

11 - 12

1 2

B

3

E

4

C

15 14

D F

13

12

A333050

11 10 8 7

9 6

5

S197440

9803/3270

Issue 2

Section E

Hydraulics

Section E

11 - 13

Loader Valve

11 - 13

Standard Spool Manual Dismantling and Assembly

When Assembling

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

When fitting bolt 9, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.


Make sure that all the parts move freely, check that item 10 does not interfere with item 13.

• • •

Renew seal 3 and 'O' rings 4 and 15. Make sure the 'O' rings and wiper seals are not trapped or damaged.


All or any of the above points may result in possible problems with the valve. When 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 be taken to ensure that the spool 8 is not damaged when removing it from the valve block.

* To fit new seal 15, fit seal 15 and seal plate 14 to the valve block section but do not torque tighten capscrews 5 at this stage. 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. Torque tighten capscrew 5 on completion. * From machine serial number 481007, new backhoe valve blocks have been introduced. The new valve blocks have landed spools with boots. Sintered breathers D are fitted in place of wiper seals 3. This improvement will prevent the ingress of dirt and prolongs the service life of the lipseal. 1

Fit the boot E to the seal plate C.

Hold the spool in clamp 992/10100, unscrew bolt 9 and remove spring 12, spacer 10 and cups 11 and 13.

2

Fit a new lipseal F into the valve block, ensure square. Fit breather D on top of lipseal.

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).

3

Fit the seal plate and boot assembly to valve block section but do not torque tighten capscrews B at this stage. Ensure breather 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 B to 7 lbf ft (9.5Nm).

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

9803/3270

Nm 5.4 9.5 9.5

kgf m 0.6 0.96 0.96

lbf ft 4 7 7

Issue 2*

Section E

Hydraulics

Section E

11 - 14

Loader Valve

11 - 14

1

B

E

2 4

C

3 5 6

D

22

7

F

13 17

21

A333050

16

20 12 19 18

25 15

11 24 10 14 9

23 8 S197460

9803/3270

Issue 2

Section E

Hydraulics

Section E

11 - 15

Loader Valve

11 - 15

* Float

Spool Manual

Dismantling and Assembly

When Assembling


When fitting detent pin 22, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.


Apply grease liberally balls 12, this will help to hold the balls in position whilst assembling.

• • •

Renew seal 3 and 'O' rings 4, 6 and 17. Make sure the 'O' rings and wiper seals are not trapped or damaged.


All or any of the above points may result in possible problems with the valve. When Dismantling

Remove the lever linkage from the tang (lever) end of the spool. 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.

* To fit new seal 17, fit seal 17 and seal plate 16 to the valve block section but do not torque tighten capscrews 8 at this stage. 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. Torque tighten capscrew 8 on completion. * From machine serial number 481007, new backhoe valve blocks have been introduced. The new valve blocks have landed spools with boots. Sintered breathers D are fitted in place of wiper seals 3. This improvement will prevent the ingress of dirt and prolongs the service life of the lipseal. 1


2


3

Fit the seal plate and boot assembly to valve block but do not torque tighten capscrews B at this stage. Ensure breather locates into seal plate.

4

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


6

Torque tighten cap screws B to 7 lbf ft (9.5Nm).

Care must be taken to ensure that the spool 15 is not damaged when removing it from the valve block. Carefully remove collar 11 and collect detent balls 12. Using tool 992/10100 to hold the spool, remove circlip 18, plug 19, ball 20 and spring 21. Unscrew detent pin 22 and remove spring 24 and cups 23 and 25. Check for surface contamination on the under side of the seal plates 2 and 16. 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).

Re-connect the lever mechanism to the tang (lever) end of the spool. 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 8 22

9803/3270

Nm 9.5 9.5 9.5

kgf m 0.96 0.96 0.96

lbf ft 7 7 7

Issue 2*

Section E

Hydraulics

Section E

11 - 16

Loader Valve

11 - 16

2

1

3

B

4

E C

11 10

D

9

F

6 18

A333050

17

16 12

8 5 15 14 13 7

S197450

9803/3270

Issue 2

Section E

Hydraulics

Section E

11 - 17

Loader Valve

11 - 17

Electric Detent Spool Manual Dismantling and Assembly

When Assembling


When fitting spool end 15, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.


Make sure that the chamfer on item 14 faces away from the solenoid, item 6.

• • •

Renew seal 3 and 'O' rings 4 and 11. Make sure the 'O' rings and wiper seals are not trapped or damaged.


All or any of the above points may result in possible problems with the valve. 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, 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).

* To

fit new seal 11, fit seal 11 and seal plate 10 to the valve block section but do not torque tighten capscrews 5 at this stage. 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. Torque tighten capscrew 5 on completion. From machine serial number 481007, new backhoe valve blocks have been introduced. The new valve blocks have landed spools with boots. Sintered breathers D are fitted in place of wiper seals 3. This improvement will prevent the ingress of dirt and prolongs the service life of the lipseal. 1


2


3


4


5


6

Torque tighten cap screws B to 7 lbf ft (9.5 Nm).

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

9803/3270

Nm 5.4 9.5 9.5

kgf m 0.6 0.96 0.96

lbf ft 4 7 7

Issue 2*

Section E

Hydraulics

Section E

11 - 18

Loader Valve

11 - 18

9 7

10

6

11

5

8 4

3

2

1

S337610

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 19

Loader Valve

11 - 19

Standard Spool Servo Dismantling and Assembly

When Assembling

It is possible to remove a spool without removing the valve block. The spring 5 is at the bottom so the spool must be removed from the bottom.

Renew 'O' rings 7 and 11. Make sure the 'O' ring seals are not trapped or damaged.



For assembly the sequence should be reversed. Make sure that all the parts move freely. The following points MUST be avoided when dismantling and assembling the valve:

• • •



Run the engine and inspect the valve for external leaks. Torque Settings Item 1 3 9

Nm 9.5 9.5 9.5

kgf m 0.96 0.96 0.96

lbf ft 7 7 7

When Dismantling Care must be taken to ensure that the spool 8 is not damaged when removing it from the valve block. Hold the spool in clamp 992/10100, unscrew bolt 3 and remove spring 5, spring seats 4 and 6. Check for surface contamination on the under side of the end caps 2 and 10. Clean if necessary.

9803/3270

Issue 2

Section E

Hydraulics

Section E

11 - 20

Loader Valve

11 - 20

24

17

18

12

11

19 10

16 20

15

9 8

21

7

6 5 4

22

3 14

23 1 13

2 A337620

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 21

Loader Valve

11 - 21

Float Spool Servo Dismantling and Assembly

When Assembling

It is possible to remove a spool without removing the valve block. Springs are fitted to both ends of the spool so both end caps 2 and 17 need to be removed. Whichever bolt comes undone 11 or 19 will determine which direction the spool can be removed. If the spool has to be removed from the top, the fuse and relay panel will also have to be removed

Renew 'O' ring seals 3, 16 and 23. Make sure the 'O' ring seals are not trapped or damaged.


Apply grease liberally to balls 7, this will help to hold the balls in position whilst assembling.


Run the engine and inspect the valve for external leaks.


Torque Settings

• • •

Item 1 11 18 19



When fitting detent sleeve 10, and bolts 11 and 19 clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.

Nm 9.5 9.5 9.5 9.5

kgf m 0.96 0.96 0.96 0.96

lbf ft 7.0 7.0 7.0 7.0

When Dismantling Carefully remove collar 4 and collect four detent balls 7.

* Do

not dismantle items 5 to 9 unless there is a detent problem, treat as an asembly. If required, use tool 992/10100 to hold the spool, remove circlip 5, plug 6, ball 8 and spring 9. Use a spanner to hold adaptor 12 unscrew detent sleeve 10.

Unscrew bolt 11, remove adaptor 12, spring 13 and spring seat 14. Undo bolt 19, remove spring seat 20, spring 21 and spring seat 22. Care must be taken to ensure that the spool 24 is not damaged when removing it from the valve block. Check for surface contamination on the under side of the end caps 2, 15 and 17.

9803/3270

Issue 2*

Section E

Hydraulics

Section E

11 - 22

Loader Valve

11 - 22

9

7

6 8

5

10 4 11

3

2 14 13 12

S337630

1

9803/3270

Issue 1

Section E

Hydraulics

Section E

11 - 23

Loader Valve

11 - 23

Electrical Spool Servo Dismantling and Assembly

When Assembling

It is possible to remove a spool without removing the valve block. The spring 5 is at the bottom so the spool must be removed from the bottom.

Renew 'O' ring seals 7 and 10. Make sure the 'O' ring seals are not trapped or damaged. Renew ‘O’ ring seals on the solenoid 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:

• • •


All or any of the above points may result in possible problems with the valve. When Dismantling Hold the spool in clamp 992/10100, unscrew bolt 3 and remove spring seat 4, spring 5 and spring seat 6. Care must be taken to ensure that the spool 11 is not damaged when removing it from the valve block. Check for surface contamination on the under side of the seal caps 2 and 9.

When fitting bolt 3, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Threadocker and Sealer to the threads of the spool. The proportional pressure reducing valve must be replaced as a complete unit. Refit solenoid cartridge 14, place coil 13 onto the cartridge and position the coil so that the electrical connection is at the correct angle. Fit and tighten nut 12 holding coil 13 to prevent turning. Run the engine and inspect the valve for external leaks. Torque Settings Item 1 3 8 12 14

Nm 9.5 9.5 9.5 6.75 27.1

kgf m 0.96 0.96 0.96 0.70 2.76

lbf ft 7 7 7 5 20

Note: If removing a proportional pressure reducing valve from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. Switch on the starter switch, without the engine running. Switch the joystick isolator on and operate the joystick controls several times. To remove a proportional pressure reducing valve, unscrew nut 12 and remove coil 13. Unscrew solenoid cartridge 14.

9803/3270

Issue 2

Section E 11 - 30

Hydraulics

Section E

Loader Valve Variable Flow Hydraulics

11 - 30

Loader Valve Description 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.

2

3

Valve Block Identification: ITEM DESCRIPTION 1 Auxiliary (optional) service 2 Shovel service 3 Arms lift service 4 Pump inlet 5 Tank port 6 Load sense port (from valve blocks) 7 Priority load sense port (from steer unit) 8 Priority work port (to steer unit) 9 Load sense carry over port (to backhoe valve) 10 Service ports 11 Auxiliary relief valve (rods side) 12 Auxiliary relief valve (head side) 13 Priority relief valve † † Note: Steer circuit pressure is controlled by a relief valve housed in the orbitrol unit (see section H). The priority relief valve housed in the loader valve must be set at 2500 lb/in2, this will ensure it does not interfere with the operation of the relief valve housed in the orbitrol unit.

1

!

0 9

4 5

0 8

@

6 7

£ A273670

9803/3270

Issue 1

Section E

Hydraulics

Section E


11 - 31

11 - 31

Loader Valve Removal and Replacement





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.

INT-3-1-11/1

Removal 1


2


3


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

9803/3270

Issue 1

Section E

;y Hydraulics

Section E


11 - 32

Priority Inlet Section Description of 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 steer valve and received at the priority inlet section (port PRLS). The signal oil flows through port A into chamber C via gallery B.

Port P T LS PRLS PR

Description Pump Inlet Tank Load sense port (to pump) Priority Load Sense Port (from steer unit) Priority Work Port (to steer unit)

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 steering valve 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 orbitrol steer valve also houses a steer system relief valve. To ensure the relief valve in the orbitrol steer unit controls the steer system pressure, valve J is set abnormally high (172 bar; 2500 lb/in2).

11 - 32

PR

P

PRLS

;;;;; ;;;;; ;;;

EXHAUST

;;; PUMP ;;; ;;;;

LS

;;;; LOAD SENSE ;;;;

T

;;;;;;;;;;; ;;;;;;;;;;; ;;;;; ;;;;;;;;;;; ;;;;; ;;;;;;;;;;; ;;;;; ;;;;;;;;;;; ;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;; ;;;;;;;;;;; ;;;; ;;;;;;;;;;; ;;;;; ;; ;;;; ;;; ;;;;;;;;;;;; ;;;;; ;; ;;;; ;;;

PRLS

T

PR

PR

LS

P

A273940

E

A

;;

B ;;;;;;;;;;;; ;;;;; ;;;;; ;;;;;;;;;;;; ;;;;; C D ;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;; J ;;;;;;;;;;;;

A273930

9803/3270

Issue 1

Section E

;y Hydraulics

Section E


11 - 33

Priority Inlet Section Description of 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.

Port P T LS PRLS PR

11 - 33

Description Pump Inlet Tank Load sense port (to pump) Priority Load Sense Port (from steer unit) Priority Work Port (to steer unit)

PR

P

PRLS

;;;;; EXHAUST ;;;;; ;;;;

;;;;PUMP ;;;; ;;;;

LS

T

;;;;LOAD SENSE ;;;;

;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;; ;;;;;;;;;;;;; ;;;; ;; ; ;;;;;;;;;;;; ;;;; ;;; ;; ;;;;;;;;;;;; ;;;;

PRLS

T

PR

PR

LS

P

A273970

;;

;;;;;;;;;;;; ;;;; ;;;;;;;;;;;; ;;;; ;;;;;;;;;;;; ;;;;;;;;;;;;

F

G

H

4

E

D

C J

A273980

9803/3270

Issue 1

Section E

Hydraulics

Section E


11 - 34

11 - 34

Priority Inlet Section Dismantling and Assembly

7 8

1

6

5

2 3 3

3

16

17 4 4

8

5

7

5

4 14

14

15

13

13 11

11

12

12

A

10

10

9

9

18 17 S276050

16 A276060

9803/3270

Issue 1

Section E 11 - 35

Hydraulics

Section E


11 - 35

Priority Inlet Section Dismantling and Assembly

When Assembling






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.


All or any of the above points may result in possible problems with the valve. When 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 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

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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

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.

9803/3270

Issue 1

Section E 11 - 36

Hydraulics

Section E


11 - 36

Auxiliary Service Description of Operation The auxiliary valve section comprises the spool assembly A, load hold check valve assembly B, primary and secondary shuttles, items L and K respectively.

A

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.

B G E

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.

H J F 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.

A276100

PUMP

B K

K

L A

L

LOAD SENSE

A276290

9803/3270

Issue 2*

Section E

Hydraulics

Section E


11 - 37

11 - 37

Auxiliary Service 7

21


22

6

8

23

9 20

24

13 1 2 3 3

7

5

3

6

26 8 9

27

4

4

20

21

5

5

22 23

4 25

19

24

18 17 15

S276070

16 14

19

13

18

16 11

17 15 14

12 11

12 10

10

26 A276080

27 25

9803/3270

Issue 1

Section E 11 - 38

Hydraulics

Section E


11 - 38

Auxiliary Service Dismantling and Assembly

When Assembling



For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve:

• • •


All or any of the above points may result in possible problems with the valve. When 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.

9803/3270

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 use the procedure described on page E/11-45. 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 41 6 8 8 67 13.5 13.5

kgf m 4.1 0.55 0.8 0.8 6.9 1.38 1.38

lbf ft 30 4 6 6 50 10 10

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

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

Issue 1

Section E

Hydraulics

Section E


11 - 39

11 - 39

Loader Shovel Service Description of Operation The loader shovel service operates in the same manner as the auxiliary service (see page E/11-36).

30

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.

30A

The shovel service may also be fitted with a ‘return to dig’ detent solenoid 12.

12

A278920

PR

P

PRLS LS

30 30A

T A279300

9803/3270

Issue 1

Section E

Hydraulics

Section E


11 - 40

11 - 40

Loader Shovel Service Dismantling and Assembly

6

7

26 27

8

28

30

9 35

29

31 21 1

2

32 33

3 5

3

3

7 6

37

8 9 30

38

4

4

35 26

5

5

31 27 32

28

33

4

36

34 25

29

24 14 13

21 34

20 24 19 23 14

20

25

22

12

19

17

18

11 11

13 16 15

12

33 23 32 31 22 30

10

10

18 17 16 15

37

S276140

36

38 A276150

9803/3270

Issue 1

Section E 11 - 41

Hydraulics

Section E


11 - 41

Loader Shovel Service Dismantling and Assembly 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:

• • •


All or any of the above points may result in possible problems with the valve. When 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).

When Assembling 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.

Torque Settings Item Nm 1 41 6 6 10 8 15 2.7 22 11 26, 30 67 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

kgf m 4.1 0.55 0.8 0.27 1.1 6.9

lbf ft 30 4 6 2 8 50

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

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 use the procedure described on page E/11-45. ALWAYS fit three shim (item 5) in between each valve block section as shown. Run the engine and inspect the valve for external leaks.

9803/3270

Issue 1

Section E

Hydraulics

Section E


11 - 42

11 - 42

Loader Lift Service Description of Operation The loader lift service operates in the same manner as the auxiliary service (see page E/11-36).

18

A

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.

A

A278910

P

18

LS T A279430

9803/3270

Issue 1

Section E

Hydraulics

Section E


11 - 43

11 - 43

Loader Lift Service 7

31


6

32 8

33

9 27

34

18

1

2

7

3 3

6

3

5

8 9 27

29 31 32

30 4

4 5

5

33

34

28

4 26

24 22

18

17

26 25 24

10

23 22 21

20 19

13 12

16

21 25

15

20 19

14

16 15

17

23

11

13

14

12

11

29

10

A276120

S276110

30 28

9803/3270

Issue 1

Section E 11 - 44

Hydraulics

Section E


11 - 44

Loader Lift Service Dismantling and Assembly

When Assembling



For assembly the sequence should be reversed. The following points MUST be avoided when dismantling and assembling the valve:

• • •


All or any of the above points may result in possible problems with the valve. When 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.

9803/3270

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 use the procedure described on page E/11-45. 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 20 28 29 31

Nm 41 6 8 8 13.5 13.5 67

kgf m 4.1 0.55 0.8 0.8 1.38 1.38 6.9

lbf ft 30 4 6 6 10 10 50

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

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 Issue 1

Section E 11 - 45

Hydraulics

Section E


11 - 45

Valve Section - Spool Seal Assembly 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

2

3

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).

Position the spool in its central position as shown. Reassembe the centering assembly, dust boot etc as detailed previously in this section.

C

2 B

3 A276280

9803/3270

Issue 1

Section E

Hydraulics

Section E

Loader Valve 3CXE, 214E Machines Only

12 - 1

12 - 1

Description The loader valve is mounted on the chassis frame, right hand side (when viewed from rear). Standard equipment includes loader lift spool (3A) and shovel spool (3B). There is also an optional auxiliary spool (not shown) available. Linkage rods connect the spool ends to the control levers. Oil from the pump enters the loader valve at 1A via a steering priority valve. When all the spools are in neutral as shown, the oil passes around the waisted central portions of the spools and flows on to feed the excavator valve via high pressure carry over line 1B. The exhaust gallery is connected to the tank return line via port T. Component Key 3 3A 3B 1A 1B T

3A

Loader Valve Block LIft Ram Spool Shovel Ram Spool Pump Inlet High Pressure Carry Over Tank Port

3B

T

3

1B 1A

A262820

9803/3270

Issue 1

Section E

Hydraulics

Section E


12 - 2

12 - 2

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





Removal 1


2


3


4

Loosen and remove bolts B, spring washers and plain washers. Remove the loader valve.

A B

S266270

9803/3270

Issue 1

Section E

Hydraulics

Section E

;;;;; ;; ;;; ;;;;; ;; ;;;;; ;; ;; ;; ; ;;;; ; ;; ;; ; ;;;; ;; ; ; ;;;;; ;; ; ;; ;; ;;; ;; ;; ; ;; ;; ;;;;;; ;; ; ;; ;; ;; ;; ;;

Loader Valve 3CXE, 214E Machines Only Main Relief Valve (M.R.V.) Operation 12 - 3

1

Valve at Rest

The main relief valve (M.R.V.) 3B, situated in the loader valve block, provides control of both loader and excavator pressures. When a service is selected, pressure rises in the service line and back through the loader valve to the pump. The service is operating under light load and the pressure 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 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 (via cavity K and down the sides of sleeve J). Unless the pressure continues to rise, plunger A will remain on its seat. 3

Valve Moves off its Seat

When pump pressure rises to the setting of the main relief valve, 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 lower 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 into the exhaust gallery.

12 - 3

3B

G

F

K J

C D

A

H

E

B

A262700

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.

9803/3270

Issue 1

Section E

Hydraulics

Section E


12 - 4

12 - 4

Main Relief Valve

A262860

11 10

2

9

1 8

7 13 6 4

14

5

12

3

S262720

9803/3270

Issue 1

Section E 12 - 5

Hydraulics

Section E


12 - 5

Main Relief Valve Dismantling and Assembly

When Assembling






Make sure that the 'O' rings and back-up rings are fitted the correct way, items 10 and 11.

• • •

Adjust pressure setting as required.




Nm 5.4

kgf m 0.6

lbf ft 4

When 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.

S262720

9803/3270

Issue 1

Section E 12 - 6

Hydraulics

Section E


12 - 6

Auxiliary Relief Valve - FIG 1 1

G

Valve at Rest

A.R.V's are positioned in the excavator valve block in order to relieve excessive pressure in the services. 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.

F

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.

H

The force of spring F is adjustable to suit the relevant service by means of adjuster screw G. 2

J

Pilot Valve Opens

E

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

D

Main Poppet Opens

As service pressure continues to rise and oil escapes from cavity H, 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 H 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.

B K C A

S266310 (&A)

Load Hold Check Valves - FIG 2 The following text describes how the load hold check valve works in the arms raise service.

D

Operation 1 The weight of the loaded shovel 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, the pressure in parallel gallery B increases until it is greater than that in service line D.

3J

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

B 9803/3270

Issue 1

Section E 12 - 7

Hydraulics

Section E


12 - 7

Auxiliary Relief Valve

A262850

S248440

9803/3270

Issue 1

Section E 12 - 8

Hydraulics

Section E


12 - 8

Auxiliary Relief Valve Dismantling and Assembly 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:

• • •


All or any of the above points may result in possible problems with the valve. When Dismantling When removing 'O' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage to the seal grooves.

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 12, 13 and 18, 19. Adjust pressure setting as required. Torque Settings Item 1 3 5 10

Nm 5.4 - 8.2 41 - 68 5.4 - 8.2 41 - 68

kgf m 0.55 - 0.83 4.15 - 6.9 0.55 - 0.83 4.15 - 6.9

lbf ft 4-6 30 - 50 4-6 30 - 50

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.

9803/3270

Issue 1

Section E 12 - 9

Hydraulics

Section E


12 - 9

Standard Spool

A248450

S248430

9803/3270

Issue 1

Section E 12 - 10

Hydraulics

Section E


12 - 10

Standard Spool Dismantling and Assembly 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:

• • •



When Assembling Renew wiper seals 5 and 14 and ‘O’ rings 6, 15 and 18. When fitting bolt 9, clean the threads thoroughly using JCB Cleaner & Degreaser, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool. 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

When Dismantling Remove the lever linkage from the tang (lever) end of the spool.

Item 7 9

Nm 6.1 - 7.5 9.5 - 10.9

kgf m 0.62 - 0.76 0.97 - 1.11

lbf ft 4.5 - 5.5 7-8

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 5, which is a wiper seal and is a press fit in the counterbore. Care must be taken to ensure that the spool 19 is not damaged when removing it from the valve block. Check for surface contamination on the under side of the seal plates 4 and 13. 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).

9803/3270

Issue 1

Section E 12 - 11

Hydraulics

Section E


12 - 11

Float Spool

A248460

S248440

9803/3270

Issue 1

Section E 12 - 12

Hydraulics

Section E


12 - 12

Float Spool Dismantling and Assembly 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:

• • •


When Assembling Renew wiper 5 and 'O' rings 6, 20, 21 and 24. Apply grease liberally to detent pin 14 to hold detent balls 11 in position during assembly and to provide lubrication. When fitting detent pin 14, clean the threads thoroughly using JCB Cleaner & Degreaser, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.


Re-connect the lever mechanism to the tang (lever) end of the spool.

When Dismantling


Remove the lever linkage from the tang (lever) end of the spool.

Torque Settings

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 5, which is a wiper seal and is a press fit in the counterbore.

Item 9 14

Nm 6.1 - 7.5 9.5 - 10.9

kgf m 0.62 - 0.76 0.97 - 1.11

lbf ft 4.5 - 5.5 7-8

Care must be taken to ensure that the spool 25 is not damaged when removing it from the valve block. Remove retainer 7 and spacer 8. Using a suitable tool on ball 12, compress spring 13 and allow detent balls 11 to roll into their holes in the detent pin 14. Carefully remove the spool cap 10 and collect detent balls 11. Check for surface contamination on the under side of the seal plate 4 and spacer 19. 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).

9803/3270

Issue 1

Section E

Hydraulics

Section E

Loader Valve - Pressure Testing

13 - 1

13 - 1

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/in2) pressure gauge to pressure test connector A on the loader valve, (see Service Tools, Section 1).

* Note: For 3CXE, 214E & 214e machines, fit test connector (892/00264) on the inlet to the valve block and connect to test point as shown at B. 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

A

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.

D

B

352710

C

A

S266281

9803/3270

Issue 3*

Section E

Hydraulics

Section E


13 - 2

Unloader Valve

*

13 - 2

Hydraulic Speed Control (HSC)

Make sure that the hydraulic oil is at working temperature, i.e. 50°C (122°F).

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).

* 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/in2) pressure gauge to pressure test connector A.

2

With the engine running at 1500 revs/min, slowly operate arms raise or lower.

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/in2) 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/in2).

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.

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, see unloader valve assembly - dismantling and assembly

F E

A

352710

9803/3270

A

S266300

Issue 2*

Section E 13 - 5

Hydraulics

Section E


13 - 5

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.

6

7

4

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.

2

1

3 5

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: 1.1

Fit extractor cap 11 over the A.R.V. sub-assembly 7, into the valve block E.

1.2

Fit 'C' washer 12 on top of the extractor cap, but under the anti-cavitation spring seat as shown.

1.3

Unscrew the extractor cap, - the A.R.V. subassembly will withdraw with the extractor cap.

E

S196700

!

@

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 8 7 3

S162570B

Install adjusting pin 3 into setting body 2.

2 3

S162570C

9803/3270

Issue 1

Section E 13 - 6

Hydraulics

Section E


13 - 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.

3

0

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

S162570E

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.

S162570F

1

Connect a 0 to 400 bar (0 to 6000 lbf/in2) 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.

S162570F

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.

9803/3270

Issue 1

Section E 13 - 7

Hydraulics

Section E


13 - 7


Use the hand pump to raise approximately 172 bar (2500 lbf/in2) 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.

0

C

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. S162570G

9

If no pressure can be raised (see step 8) 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.

D

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.

6

The bung can be extracted using a 3/8 - 16 UNC threaded bolt.

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.

4

Note: Remember, it will not be possible to release the lock nut if there is not approximately 172 bar (2500 lbf/in2) pressure at the valve inlet.

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.

4 3

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. S162570K

9803/3270

Issue 1

Section E 13 - 8

Hydraulics Loader Valve - Pressure Testing

Section E 13 - 8


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.

9803/3270

Issue 1

Section E

Hydraulics Backhoe Valve

14 - 1 * Backhoe

Section E 14 - 1

Valve Manual Description

Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery 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. Component Key (JCB Control Pattern) 4A 4B 4C 4D 4E 4F

Slew Spool Boom Spool Stabiliser Spool Stabiliser Spool Dipper Spool Bucket Spool

Note: Machines with ISO control pattern have the boom and dipper spools interchanged.

C

B

4F

4E

4D

4C

4B

4A

A263040

A

A263020

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Backhoe Valve

14 - 1A

14 - 1A

Backhoe Valve Servo Description Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery 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.

Component Key (ISO Pattern)

If the solenoid on the stabiliser section 4C is energised, pilot pressure from D would be felt at E which would push the spool down against spring pressure.

4A 4B 4C 4D 4E 4F

Slew Spool Dipper Spool Stabiliser Spool Stabiliser Spool Boom Spool Bucket Spool

Pump flow in the neutral gallery at F passes around the spool to service port G.

Note: Machines with JCB+ control pattern have the boom and dipper spools interchanged.

When the solenoid is de-energised spring pressure overcomes pilot pressure and the spool returns to the central neutral position.

D 4D 4F

D 4C

4E

E 4B

4A

E A C

B G

G

F

A337590

9803/3270

Issue 2

Section E

Hydraulics

Section E

Backhoe Valve

14 - 2 * Backhoe

! CAUTION

Valve Manual




Removal 1


2

Remove the rear valance.

3


4


5

Loosen nuts B - do not completely remove the retaining nuts.

14 - 2

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 nuts B and lower the valve block to the ground.

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. Refer to pages E/14-10 and E/14-11.


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 (Loctite 577) applied to the threads of the adapter.

B

A 9803/3270

S266320

Issue 3*

Section E

Hydraulics

Section E

Backhoe Valve

14 - 2A

14 - 2A

J

H A

A

A

613/36011

629/30031

C

B

B Top 7

6

629/

H H

D

D

351830

F F G G E

K

E E

352690

L

9803/3270

352700

Issue 1

Section E

Hydraulics

Section E

Backhoe Valve

14 - 2B

Backhoe Valve Servo

10

Loosen mounting plate bolts H - do not completely remove the retaining bolts.


! 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.

! 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

11

Attach a suitable sling to the mounting bracket slinging point, make sure that the weight of the valve is supported by the sling.

12

Remove bolts H and lower the valve block to the ground.

13

If the pilot hose adaptors J are going to be removed, label before removing as restrictors are fitted in most positions.

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.

14 - 2B

Replacement

INT-3-1-11/1

Replacement is a reversal of the removal sequence. Removal It is recommended that the excavator valve block and the manifold blocked are removed as an assembly. The illustration is viewed from the top when disconnecting pilot hoses and solenoid valves also disconnect the pilot hoses on the bottom. 1

Operate the valve block joysticks back and forth to vent accumulator pressure.

2

Remove the rear valance.

3


4

Disconnect electrical connections B to stabiliser spools.

5

Disconnect electrical connection C to reverse alarm.

6

For access remove bolts K and tie hose guard L out of the way.

7

Disconnect hydraulic hoses to services D and inlet and tank return from the valve block, plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

8

Disconnect manifold block pilot hoses E, inlet and feed hoses F, plug all orifices to prevent ingress of dirt. The hoses should be labelled, if not label each hose before disconnecting, this will ensure correct position when refitting.

9

Disconnect electrical connections G to pilot solenoid valves.

9803/3270

Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.


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 (Loctite 577) applied to the threads of the adapter.

Issue 1

Section E 14 - 3

Hydraulics

Section E

Backhoe Valve

14 - 3

B

E C D F

A333050

S161861

9803/3270

Issue 3

Section E

Hydraulics

Section E

Backhoe Valve

14 - 4 * Backhoe

14 - 4

Valve Manual

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

* From machine serial number 481007, new backhoe valve blocks have been introduced. The new valve blocks have landed spools with boots. Sintered breathers D are fitted in place of wiper seals 11. This improvement will prevent the ingress of dirt and prolongs the service life of the lipseal.

For assembly the sequence should be reversed. Check Valves

1


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.

2


3


4


5


6

Torque tighten cap screws 9 to 7 lbf ft (9 Nm).

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 Lock and Seal to threads of screw 15. Relief Valves A.R.V's 4H to 4P appear identical but have various pressure settings (see 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 sealant (Loctite 577) applied to the threads of the adapter. Torque Settings Item 1 5 13 15 23

Nm 122 80 7 11 95

9803/3270

kgf m 12.4 8.3 0.7 1.1 10

lbf ft 90 60 5 8 70

Issue 2*

Section E

Hydraulics

Section E

Backhoe Valve

14 - 4A

14 - 4A

1 2

1

12

13

2 14

3 3

4

4H

5

4

6

5

11

7 6 7

4L 4N

4E

4D

4C

4K 4P 10

4A

4J 4X

4M

11

10

4F

9

8

9 8

9803/3270

4B

A339520

Issue 1

Section E 14 - 4B

Hydraulics

Section E

Backhoe Valve

14 - 4B

Backhoe Valve Servo Dismantling and Assembly

When Assembling


Renew 'O' ring seals 7 and 10. Make sure the 'O' ring seals are not trapped or damaged.


Renew ‘O’ ring seals on the solenoid valve 12.

Note: If removing components from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. Switch on the starter switch, without the engine running. Switch the joystick isolator on and operate the joystick controls several times.


It is possible to remove a spool without removing the valve block. The spring 5 is at the top so the spool must be removed from the top.

The pilot proportional pressure reducing valve must be changed as a complete unit 12/13. Refit solenoid spool 12, place body 13 onto the spool and position the body so that the electrical connection is at the correct angle.

Each of the identical load hold check valves can be removed as shown at 4F. Make-up check valve 4X is a smaller size but otherwise identical.

Fit and tighten nut 14 holding body 13 to prevent turning.

Ensure good condition of seating faces on poppets 4X and 4Y and on the mating faces in the valve block.

Torque Settings

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.

Item 1 3 8 12 14


Nm 9.5 9.5 9.5 27.1 6.75

kgf m 0.96 0.96 0.96 2.76 0.70

lbf ft 7 7.0 7 20 5

When Dismantling Hold the spool in clamp 992/10100, unscrew bolt 3 and remove spring seat 4, spring 5 and spring seat 6. Care must be taken to ensure that the spool is not damaged when removing it from the valve block. Check for surface contamination on the under side of the seal caps 2 and 9. To remove the pilot proportional pressure reducing valve, unscrew nut 14 and remove solenoid body 13. Unscrew solenoid spool 12. A.R.V's 4H to 4P appear identical but have various pressure settings (see Technical Data). Ensure that they are correctly adjusted and fitted in their specified positions. Relief valve dismantling and assembly procedures are detailed separately.

9803/3270

Issue 1

Section E 14 - 5

Hydraulics

Section E

Backhoe Valve

14 - 5

Auxiliary Relief Valve A.R.V's are positioned in the excavator valve block in order to relieve excessive pressure in the services. 1

Valve at Rest

Figure 1 shows the service in neutral with no forces acting on the equipment. The force of spring D acting through collar C keeps poppet B firmly held on its seat.

E

F J

Chamber J is connected to the exhaust gallery via small drilled holes H, this means the pressure in the chamber will always be at exhaust. The A.R.V. pressure setting is adjustable by means of spring D and adjusting screw E. Turning the screw clockwise compresses the spring and therefore increases the pressure setting. And conversely, turning the screw anti-clockwise releases the spring which decreases the pressure setting. 2

H D

Poppet Opens

C If the pressure in the service gallery A has reached the setting of the A.R.V., the pressure on the service side of the poppet is high enough to overcome the force of spring D so poppet B lifts off its seat. Oil in chamber J is displaced through small drilled holes H.

K

B A

G

Service pressure at A is now released into exhaust gallery K. A263070

Anti-Cavitation Operation When the service gallery is cavitating, the A.R.V. anticavitation operation allows oil from the exhaust gallery to supplement the cavitating service line.

1

Operation 1

When the ARV is subjected to normal operating pressure in service gallery A, the force of spring F and pressure in the service gallery acting on the bottom face of anti-cavitation cone G keep the cone held firmly on its seat. 2

Operation 2

When the service gallery is cavitating, the pressure in exhaust gallery K is sufficient to overcome the force of spring F. The cone and its assembly move down allowing oil in the exhaust gallery to enter the service gallery and limit the effects of cavitation. When the service gallery is no longer cavitating, compressed spring F will return to its relaxed position and thus bring the anti-cavitation cone back onto its seat.

9803/3270

Issue 1

Section E

Hydraulics

Section E

Backhoe Valve

14 - 6

14 - 6

Auxiliary Relief Valves

4Q 4N

4L

4J

4P

4K

4H

4M

A262520

B

A

S161700

9803/3270

Issue 1

Section E

Hydraulics

Section E

Backhoe Valve

14 - 7

14 - 7

Auxiliary Relief Valves Dismantling and Assembly

A.R.V. Position Key Control Layout

Eight A.R.V's are fitted at positions 4H to 4Q. These are identical in design but have various pressure settings (see Technical Data).

JCB

ISO

Case

Ford

Slew Right

4H

4H

4H

4H

Note: Valve 4Q is only fitted to machines equipped with a Powerbreaker.

Slew Left

4J

4J

4J

4J

Boom Rod

4K

4M

4M

4K


Boom Head

4L

4N

4N

4L

Dipper Rod

4N

4L

4K

4N

Dipper Head

4M

4K

4L

4M

Bucket Rod

4Q

4Q

4Q

4P

When Dismantling

Bucket Head

4P

4P

4P

4Q

Dismantle sub-assembly 14 from item 1 using a special tool (see Service Tools, Section 1). The special spanner locates in cross holes B.

Note: The bucket rod side A.R.V. is only fitted to machines equipped with a Powerbreaker.


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. When Assembling 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, Section 1), until its shoulder seats firmly against item 1. Pressure test the valve using the procedure described in Backhoe Valve - Pressure Testing. Torque Settings Item 1 3

Nm 65 24

9803/3270

kgf m 6.6 2.5

lbf ft 48 18

Issue 1

Section E

Hydraulics

Section E

Backhoe Valve

14 - 8

14 - 8

Hydraclamp 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 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.

D

C

H

A

G B

DRAIN PORT

CLAMP PORT

F E

E S270680

62 9803/3270

A270690

Issue 1

Section E

Hydraulics

Section E

Backhoe Valve

14 - 9

14 - 9

Hydraclamp Valve - (Sideshift Machines) Dismantling and Assembly

When Assembling


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

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.

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). For information, the hydraclamp solenoid valve is the same type as the 'Hydraulic Speed Control' solenoid valve, shown on page E/11-10.

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).

Check the operation of the electric hydraclamp, see page E/14-8 for a description of operation.

When Dismantling

Torque Settings

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).

Item 1 3 5 11 13

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.

Nm 13.5 24.5 13.5 5.5 24.5

kgf m 1.4 2.5 1.4 0.5 2.5

lbf ft 10 18 10z 4 18

14

13 12 11

A 2 10 9

1 2A

2 4

3 5

6

7

8 2A S217500

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Backhoe Valve

14 - 10

14 - 10

Hoses and Pipes - Sideshift Valve Refer to page E/14-2 for valve block removal and replacement procedure. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal.

CROWD

STABILISER

BOOM

DIPPER

SLEW

CLAMP

BOOM

BOOM

DIPPER

DIPPER

CROWD

CROWD SLEW

SLEW

CROWD

BOOM

DIPPER

STABILISER

SLEW

S270740

ISO EXCAVATOR VALVE

CROWD

DIPPER

STABILISER

BOOM

SLEW

CLAMP

BOOM

BOOM

DIPPER

DIPPER

CROWD

CROWD

SLEW

SLEW

CROWD

DIPPER

STABILISER

BOOM

SLEW

S270750

JCB EXCAVATOR VALVE 9803/3270

Issue 1

Section E

Hydraulics

Section E

Backhoe Valve

14 - 11

14 - 11

Hoses and Pipes - Centremount Valve Refer to page E/14-2 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

STABILISER BOOM

DIPPER

SLEW

S273370

ISO EXCAVATOR VALVE

CROWD

DIPPER

STABILISER

BOOM SLEW

CROWD

STABILISER DIPPER

BOOM

SLEW

S273380

JCB EXCAVATOR VALVE 9803/3270

Issue 1

Section E 14 - 12

Hydraulics

Section E

Backhoe Valve - Pressure testing

14 - 12

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 pages E/13-5 to E/13-8 for the correct pressure test procedures.

6

7

4

2

1

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.

9803/3270

3 5

S196700

Issue 1

Section E

Hydraulics

Section E

15 - 1

Auxiliary Valve

15 - 1

Auxiliary Valve Servo Description In the neutral circuit, hydraulic oil from the pump enters the auxiliary valve at A and flows around the waisted central portions of spools 2A and 2B (all in the neutral position) and flows back to tank via the high pressure carry over line B.

Component Key 2A Auxiliary 1 (extending dipper, clam) 2B Auxiliary 2

Oil also fills the parallel gallery C but is not at a high enough pressure to open the load hold check valves D. The exhaust gallery is connected to the tank return line T. When a solenoid is energised, pilot pressure at E is felt on spool F which pushes the spool down against spring pressure. Pump flow in the neutral gallery passes around the spool and out a service port. When the solenoid is de-energised spring pressure overcomes pilot pressure and the spool returns to the central neutral position.

B

E

F

2B

2A A

T D C A337870

9803/3270

Issue 3

Section E

Hydraulics

Section E

15 - 2

Auxiliary Valve

15 - 2

G F B

G

J

F

B

A

E

351840

C D

9803/3270

Issue 1

Section E

Hydraulics

Section E

15 - 3

Auxiliary Valve

15 - 3

Auxiliary Valve Servo Removal and Replacement






Removal 1

Operate the valve block joystick levers back and forth to vent residual pressure.

2


3

Disconnect four electrical connections B to auxiliary spool.

4

Disconnect hydraulic hoses to services C, inlet D, tank return E and high pressure carry over J from the valve block, plug all orifices to prevent ingress of dirt. Label each hose before disconnecting, this will ensure correct position when refitting.

5

Loosen and remove bolts F, remove the loader valve assembly and washers G.

9803/3270

Issue 1

Section E

Hydraulics

Section E

15 - 4

Auxiliary Valve

15 - 4

1 8 9 10 2

3 4 5

2A

6 7

2E 2B

2C

2D

2F

A339500

9803/3270

Issue 1

Section E

Hydraulics

Section E

15 - 5

Auxiliary Valve

15 - 5

Auxiliary Valve Servo Dismantling and Assembly

When Assembling


Renew 'O' ring seal 7. Make sure the 'O' ring seal is not trapped or damaged.

It is recommended the valve block is removed to remove spools. As springs are fitted to both ends of the spools there will not be enough access to remove a spool if the spool has to be removed towards the rear of the machine.

Renew ‘O’ ring seal on the solenoid valve. When fitting bolt 3, clean the threads thoroughly using Super Clean Safety Solvent, leave it for 10 minutes then apply a small quantity of JCB Lock and Seal to the threads of the spool.

For assembly the sequence should be reversed. Spools 2A, and 2B are identical but must not be interchanged as they are matched to their bores.

The proportional pressure reducing valve must be replaced as a complete unit. Refit solenoid spool 10, place body 9 onto the spool and position the body so that the electrical connection is at the correct angle.

When Dismantling

Fit and tighten nut 8 holding body 9 to prevent turning.

Hold the spool in clamp 992/10100, unscrew bolt 3 and remove spring seat 4, spring 5 and spring seat 6.

* Care must be taken to ensure that the spool 2A is not damaged when removing it from the valve block.

If the valve sections are separated, renew all seals and evenly torque tighten tie rods 11 and 12. Run the engine and inspect the valve for external leaks.

Check for surface contamination on the under side of the seal caps 2. Note: If removing a proportional pressure reducing valve from a valve block that is fitted on a machine the pilot circuit accumulator pressure must be vented first. Switch on the starter switch, without the engine running. Switch the joystick isolator on and operate the joystick controls several times.

Torque Settings Item 1 3 8 10 * 11 * 12

Nm 9.5 9.5 6.75 27.1 19 44.75

kgf m 0.96 0.96 0.70 2.76 2.62 6.18

lbf ft 7 7 5 20 14 33

To remove a proportional pressure reducing valve, unscrew nut 8 and remove body 9. Unscrew solenoid spool 10. A.R.V's 2C to 2F appear identical but have various pressure settings (see Technical Data). Ensure that they are correctly adjusted and fitted in their specified positions. Relief valve dismantling and assembly procedures are detailed separately.

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Backhoe Valve Variable Flow Hydraulics

16 - 1

16 - 1

Description The backhoe valve is mounted on the chassis frame at the rear of the machine.

Shuttle 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.

Stack type valves are load sensing pressure compensated valves. They control the volume, direction of the oil flow and maintain a constant oil flow regardless of changing load pressures. The valve block comprises of various valve sections specially suited to the different backhoe services, (boom, dipper, swing etc.).

The primary shuttle 18 compares the pressure 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.

For valve block identification see Technical Data page.

The secondary shuttle operates the same as the primary shuttle but compares pressure signals between 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.

A 30

B

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 spool in the pump adds margin pressure to the load requirement. The single highest shuttle signal pressure plus margin pressure governs pump output.

37 18 17

P

The pump will not change output until the shuttle network identifies a different shuttle signal.

LS T

45 STEER VALVE

P PUMP

9 LOADER VALVE 37

B

A 18

17 25 BACKHOE VALVE 9803/3270

A316510

Issue 2

Section E 16 - 2

Hydraulics Backhoe Valve Variable Flow Hydraulics

Section E 16 - 2

Testing Shuttle Signal Network 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 2 3 4 5 6 7 8 9 10 11

Bucket Dipper Right Stabiliser Left Stabiliser Boom Slew Extradig Lift Shovel Auxiliary 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.

9803/3270

Issue 1

Section E 16 - 3

Hydraulics

Section E


16 - 3

Backhoe Valve Removal and Replacement

A

B

C

C

C S278930

9803/3270

Issue 1

Section E

Hydraulics

Section E


16 - 4

16 - 4

Backhoe Valve Removal and Replacement


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 phased in same position as removal.


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.

After replacement check the auxiliary relief valve (A.R.V.) pressure settings.

2


Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter.

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


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.


7

Remove nuts C and lower the valve block to the ground.

9803/3270

Issue 1

Section E

Hydraulics

Section E 17 - 1

Hose Burst Protection Valve

17 - 1

Boom & Dipper Principle of Operation The small letter annotations A, B, X, and Y are stamped on the valve.

X

Y

C 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.

E

A

B

BACKHOE VALVE

;;;; ;;;; ;;;; ;;; ;;;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ;; ; ;;;; ;;; ;;;; ;; ;; ;; ;; ; ;; ; ;; ; ;; ;;;; ;;; ;;;; ;;;; ;; ; ; ;; ;;;;;;; ; ;;; ; ;;; ;;;; ;;; ; ;; ;; ;;;; ; ; ;;; ;; ;;; ;;;; ;;; ;;;; ;;;; ;;;; ;; ;;;;;;;; ;;

A323040

;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; (A) (X) (B) ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; D ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; C ;;;;;;;;;;;;;;;;;;;;;;;;;; E ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;; ;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;; ; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;; ;;;;;;; ; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;; ;;;;;;; ; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;; ;;;;;;; ; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; (Y) ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;

A322950

9803/3270

Issue 1

Section E

Hydraulics

Section E 17 - 2


17 - 2

Boom & Dipper Principle of Operation

BOOM RAM

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.

X

Y

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.

E

A

B

A323041 BACKHOE VALVE

;;;;;;; ;; ;; ;; ;; ; ;; ;; ;; ; ;; ;; ;; ; ;; ;; ;;;;;;; ;; ;; ; ;; ;; ; ; ;; ;; ;;;;;;; ;; ; ;; ; ;; ;;;;;;; ; ;;; ; ;;; ;;;;;;; ;; ;; ;;; ;; ;;; ;;;;;;; ;; ;; ;;;;;;; ;; ; ;;;;;;; ;;;;;;; ;;;;;;;

;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; (A) (X) (B) ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; E ;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;; H ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;; G ;;;;;;;; ;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;; ;; ;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;; ;;;;;; ;; ;;;;;;;; ;; ;; ;; ;;;;;; ;; ;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;; ;; ;;;;;;;; ;; ;; ;; ;;;;;; ;; ;;;; ;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;; ;; ;;;;;;;;;;;; ;; ;;;;;;;;;;;;;; ;;;; ;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; F J ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; (Y) ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;; ;;;;;

9803/3270

A322960

Issue 1

Section E

Hydraulics

Section E 17 - 3


17 - 3


BOOM RAM

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.

X

Y

L H F

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.

K

A

B

;;;; ;;;;; ;;;; ;; ;; ;; ;; ;; ;;; ;;;;; ;; ;; ;; ;; ; ;; ;; ;; ;;; ;;;;; ;; ;;;; ;; ;; ;; ; ;; ; ;; ;; ;; ;;; ;;;;; ;;;; ;; ; ;;;; ;; ;; ; ; ;; ;; ; ;; ; ;; ;;; ; ;;;;; ; ;;; ;;; ;;;; ;; ;; ; ;; ; ;; ;;; ; ;;;;; ;;; ;; ;;; ;;;; ;;; ;;;;; ;;;;; ;;;; ;;;;; ;; ;;;;

A323042

BACKHOE VALVE

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (A) (X) (B) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ; H ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;; ;;;;; ;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;; ;;;;; ;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;; ;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; F ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;; (Y) ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; L ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; K ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

J

;;;;; ;; A322970

9803/3270

Issue 1

Section E

Hydraulics

Section E 17 - 4


17 - 4


BOOM RAM

Hose Burst 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.

X

Y

C

Oil trapped between the valve and the ram will prevent movement of the load. To lower the load, see Lowering The Load.

E

; ; A

B ;;; ;;; ;;;

;;;; ;;;;; ;;; ;;;; ;; ;; ;; ;; ; ;;;;; ;;;; ;; ; ;; ;; ; ;; ;; ;;;;; ;;;; ;;; ;; ;; ;; ;; ; ;; ; ;; ;; ; ;;;;; ;;;; ;;; ;; ; ; ;;;; ;; ;;;;;; ;;;;; ; ;;; ; ;;; ;;;; ;;; ;; ; ;;;; ;; ; ;; ; ; ;;;;; ;;; ;; ;;; ;;;; ;;; ;;;;; ;;;;; ;;;; ;;;;; ;; ;;;;

A323043

BACKHOE VALVE

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (A) (X) (B) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;; ; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (Y) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

D

C

A

B

;;;;; ;; A322980

9803/3270

Issue 1

Section E

Hydraulics

Section E 17 - 5


17 - 5

Loader Principle of Operation 22

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.

E

;y;; ;y yy C2

B

P

A

Oil from the lower side of the ram returns to tank via port P and the loader valve block.

V2

T

A323090

9

;;;;; ;;;;; ;; ;;;;; ;; ;;;;; ;; ;;;; ;; ;;;;;; ; ;; ;;; ;;; ;;;;;; ;;;; ;;;;; ;;;;;; ;;;;;; ;;;;; ;;;; ;;;; ;;; ;;; ;;;;; ;;;; ; ; ; ;; ;; ;; ;; ;; ;; ;;; ;;;; ;; ;;;; ; ;; ;;;;;;;;;;;; ;; ;; ;; ;; ;; ;;;;;;;;;; ; ;; ;; ;;;; ; ;;; ;; ;; ;; ;;;;; ;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; 9 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (C2);;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (V2) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (P) (T) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;; ;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;; ;; ;;; ;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;; ;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;; ;;;;;; ;; ; ;;;;;;;;;;;;;; ;; ;;; ; ; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;; (E) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

;;;; ;;;;;;;;;; B

9803/3270

A

A322990

Issue 1

Section E

Hydraulics

Section E 17 - 6


17 - 6

Loader Principle of Operation Operation 2 - Load Lower

22

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.

L

;y;; ;y yy J

C2

P

D

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.

C

H

G

T

V2

A323091

9

Threads F and the one-way check valve ball L act as restrictors to 'dampen' any adverse effects of operating the control levers erratically.

;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;; ;; ;;;;;; ; ;;; ;;; ;;;;;; ;;;; ;;;;;;;; ;;;;;; ;;;;;;;;;; ;;;;; ;;;; ;;; ;;; ;;;;;;;; ;; ;;; ;;;; ;; ;;;; ; ;; ;;;;;;;; ;; ;;;; ;;; ;; ; ;; ;; ; ;; ; ; ; ;; ; ;; ;;;;; ;;; ;; ;;;;;;;;;;; ;;;;; ;;;;;;;; ;;

;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;; 9 ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; C ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;; ;; ;;;; ;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;; ;; ;;;; ;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;; ; ;; ;; ;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;; ;;; (C2);;;;;;;; ;;;;;;;;;; ;; ;;;; ;;;;; ;;;;;;;;(V2) ;;; ;;;;;;;; ;;;;;;;;;;; (P) (T) ;;; ;;;;;;; ;;; ;;;;;;; ;;; ;;; ;;;;; ;;;; ;;;;;;; ;;; ;;;;;;;; ;;; ;;;;;; ;;; ;; ;; ;;;;;;;; ;;;;;;;; ;;;;;;; ;;;; ;;;;;;;;;;;;;; ;;;; ; ; ;; ; ;; ; ;;;;;;;;;;;;;;;;; ;;; ;;;;; ;;;;;;;;;;;; ;;;;;;; ;;;; ;;;;;;;;;;;;;; ;;;;;; ;;;;;;;;;;;;;; ;;;;;;; ;;;; ;;;;; ;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;; ;;; ; ; ;;;;;;; ;;;; ;;;;; ;;;; ;;;;;;;; ;;;;;;;;;;;;;; (E)

;;;; ;;;;;;;;;; L

9803/3270

D

F

G

N

B

A

J

H

A323000

Q

Issue 1

Section E

Hydraulics

Section E 17 - 7


17 - 7


Operation 4 - 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.

;y;; y ; yy J

C2

Note: Oil exhausted via port V2 will not reduce to low pressure until the A.R.V. in the valve block 9 also opens.

P

H

T

V2

A323092

9

;;;;; ;; ;;;;; ;; ;;;;; ;; ;;;; ;; ;;;;;; ; ;; ;;; ;;; ;;;;;; ;;;; ;;;;; ;;;;;; ;;;;;; ;;;;; ;;;; ;;;; ;;; ;;; ;; ;; ;; ;;;;; ;;;; ; ; ; ;; ;;;;; ;; ;; ;;;; ;;;; ; ;; ;; ;; ;; ;;;;;;;;;;;; ;; ;; ; ; ; ;; ; ;; ; ; ;; ;;;;;;;;; ;; ;; ;;;;;;;;; ;;;;; ;; ; ; ;; ;; ;;;; ;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; 9 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (C2);;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (V2) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (P) (T) ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;; ;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;; ;;; ;;; ;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;; ;;;; ;;;;;;;;;;;;;; ;;; ;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; (E) ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; B

9803/3270

A

J

H

A323000

Issue 1

Section E

Hydraulics

Section E 17 - 8


17 - 8


Operation 3 - Hose Burst 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.

K

L

;y;; y ; yy C2

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.

J

B A

P

H

G

T

V2

;;; ;;; ;;;

A323093

9

; ; ; ;;; ;;; ;;;;;; ;;;;; ;;;; ;; ; ; ;;;; ;;;;;; ;;;;;; ;;;;; ;;;; ;;; ;;;; ;;; ; ;; ;;; ;;;; ;; ; ;; ;;;;

;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; 9 ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;; ;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;; ;;;;;;;;;;;;;;; ;;;;;;;; ;;;;;;;;;;; ;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;; ;;; ;;;;;;;;(V2) ;;;;;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;; ;; (C2);;;;;;;;;;;;;;;;;;;;;;;;; ;; ;;; ;;;;;;;; ;;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;; ;;; (P) (T) ;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;; ;;;;;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;; ;;;;; ;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;; ;;; ;;;;;;; ;;; ;; ; ;; ; ; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;; ;;; ;;;;; ;;; ;;;;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;; ;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;;;;;;; ;; ;;; ;; ; ; ;;;;; ;;;;; ;;;;;;; ;;;;;;;; ;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; (E)

;; ; ; ; ;; ; ;; ; ; ;; ;;; ;; ; ;; ;; ; ; ; ; ;; ;;;;;;;;;; ;;;;; ;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;;;; ;;;;;;;;;; K

9803/3270

L

G

B

A

J

H

A323020

Issue 1

Section E

Hydraulics

17 - 9


17 - 9

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

Section E

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.

S320930

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, see page E/17-11) or a new end cap and valve assembly fitted (Boom HBPV, see page E/17-12), 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)

A

1 2

C

3

D S170582

Remove cap A and pierce the warning label. If a hose has burst, position a suitable container to catch the oil. 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)

B

1 2 3

A171340

A171340

Remove cap C from both HCPV check valves on the loader lift arms. If a hose has burst, position a suitable container to catch the oil. 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

9803/3270

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

Issue 1

Section E

Hydraulics

Section E 17 - 10


17 - 10

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.

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

GEN-1-2



Removal


1


After refitting the valve to the machine, ensure that the valve operates correctly, see previous page for Checking Hose Burst Protection Valve.

Note: See previous page for lowering a load with engine failure or a burst hose. 2

Turn the manual over-ride screw fully clockwise, see previous page.

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.

A

A 324250

A 323590 A260734

9803/3270

Issue 1

Section E 17 - 11

Hydraulics

Section E 17 - 11


Dismantling and Assembly 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.

Assembling 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 the Pressure Testing.

E

B

F

325780

11 A183490

9803/3270

Issue 1

Section E

Hydraulics Hose Burst Protection Valve

17 - 12

Section E 17 - 12

Dismantling and Assembly 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, see Checking Hose Protection Valve.

A

B

9803/3270

S327320

Issue 1

Section E

Hydraulics

Section E 17 - 13


17 - 13

Pressure Testing - Loader Arms 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:

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

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.

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.

A J

B

G

K

E

D C F 327330

9803/3270

Issue 1

Section E

Hydraulics Hose Burst Protection Valve

17 - 14

Section E 17 - 14

Pressure Testing - Loader Arms 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/in2) 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/in2).

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/in2).

c

Replace the cap and washer.

d

Repeat pressure test, adjust as necessary.

9803/3270

Issue 1

Section E

Hydraulics

Section E

Servo Command Lowering The Loader Arms and Boom

18 - 1

18 - 1

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/hydraulic failure or electrical failure; we recommend that only a competent maintenance engineer perform the procedures.

Electrical failure

Machines with Hose Burst Protection Valve fitted, see page E/17-9.

1

Remove the protective cover and screw the manual override C fully in.

In the event of an engine, hydraulic or electrical failure an accumulator provides enough pilot pressure to put the machine into a safe condition, ie. lower the boom and loader arms.

2

To lower the loader arms, with the seat facing forward push the right hand joystick forward A.

3

Remove the protective cover and screw the manual override C and D fully in.

4

To lower the boom, with the seat facing the rear:

! 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

After lowering a load do not use the machine until the manual over-ride screw has been reset and the fault rectified, otherwise the machine will not operate as intended.

JCB Plus Pattern - push the left hand joystick towards the rear of the machine B. ISO Plus Pattern - push the right hand joystick towards the rear of the machine A.

Engine or hydraulic failure 1

Turn the starter to the ON position.

2

To lower the loader arms, with the seat facing forward push the right hand joystick forward A.

3

To lower the boom, with the seat facing the rear: JCB Plus Pattern - push the left hand joystick towards the rear of the machine B. ISO Plus Pattern - push the right hand joystick towards the rear of the machine A.

4

When the loader arms and/or boom have been lowered, switch OFF the starter switch.

C

D

B A

351590

9803/3270

Issue 1

Section E 19 - 1

Hydraulics

Section E

Servo Command

19 - 1

A

B

B

C

D

G F

E E

9803/3270

Issue 1

Section E

Hydraulics

Section E

Servo Command

19 - 2

19 - 2

Pilot Hose Removal and Replacement The following details the procedure for the removal of one pilot hose.

9

Disconnect the two hoses, tie string G to the new hose and pull through protective shroud.

1

With the starter switched ON operate the controls to dissipate accumulator.

10

Connect hose to manifold block D and fit tie wraps E.

11 2

Release the seat clamp bolts A.

Push hose through seat shroud, do not connect to control lever at this stage.

3

Remove tie wraps B securing hose cluster to seat.

12

4

Raise the seat arm, disconnect and plug the hose that requires replacing C. If more than one hose needs to be disconnected make sure the hoses are labelled, this will ensure correct position when refitting.

To ensure the hoses are phased correctly through the seat pedestal, turn the seat to face the left hand side of the machine. Position the hoses so that the markers on the hoses align with the seat clamp A, fit clamp.

13

Connect hose/s to joystick control lever C as labelled.

14

Fit tie wraps B securing hose cluster to seat.

5

Disconnect the hose that requires replacing at the manifold D. Tie a length a strong string to the hose at the manifold connection.

6

From underneath the machine, remove two tie wraps E fitted to the hose cluster protective shroud.

7

From the cab, pull the hose through, untie the string and pull the string back through the seat pedestal to protective shroud as shown at G.

8

From under the machine, push the old hose straight connector through the seat pedestal into the cab. Connect the new hose to the old hose with adaptor 1604/0002 F and pull back through the seat pedestal, as shown at G.

Hose Connections Manifold/Valve block C1 C2 C3 C4 Excavtor dipper spool bottom Excavator dipper spool top Excavator slew spool bottom Excavator slew spool top A1 A2 A3 A4 B1 B2 B3 B4

9803/3270

Controller/Valve block Right 3 Right 4 Right 1 Right 2 Left 1 Left 2 Left 3 Left 4 Loader lift ram spool top Loader lift ram Sspool bottom Loader shovel spool bottom Loader shovel spool top Excavator boom spool top Excavator boom spool bottom Excavator bucket spool top Excavator bucket spool bottom

Issue 1

Section E

Hydraulics

Section E

Rams

20 - 1

20 - 1

Removal and Replacement Loader Lift Ram

B

A

C

F G E

D

S266330

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

20 - 2

20 - 2

Removal and Replacement Loader Lift Ram Removal

Replacement

! 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.

! 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.

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.

INT-3-1-10/1

! DANGER

Coat pivot pins with anti-rust lubricant.

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.

Make sure that the head of item D is on the engine side.

INT-3-1-11/1

1st 2nd 3rd 4th

3

Assembly sequence for shim F and klipring:


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

Coat mainframe bores with grease.

Label and then remove the lift ram hoses A. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.

*

shim ram shim (as required) 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.)

! 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 993/68100 to remove pivot pin G.

9

Remove the lift ram.

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

21 - 1

21 - 1

Removal and Replacement Loader Shovel Ram

A

B

D

C

D E C

B C

B

B

E C

S266340

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

21 - 2

21 - 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.




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.

INT-3-1-11/1

3


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.


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.

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

22 - 1

22 - 1

Removal and Replacement - Slew Ram

1

Y

7 3 10

2A 2

10

6

8 5

9

4 S254901

9803/3270

Issue 2

Section E

Hydraulics

Section E

Rams

22 - 2

22 - 2

Removal and Replacement Slew Ram Removal

Inspection

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.

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.

! 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.

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

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.


8

9


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.

Attach suitable lifting straps to the slew ram assembly. Note that the weight of the slew ram assembly is approximately 44 kg (97 lbs).

When fully assembled, apply grease at each grease nipple BEFORE operating the machine.

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.

Torque Setting Item Nm lb ft 2 650 480

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.

9803/3270

kgf m 66.3

Issue 1

Section E

Hydraulics

Section E

Rams

23 - 1

23 - 1

Removal and Replacement * Stabiliser Ram (Centremount) Removal

*1

*2

Replacement

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

3



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.



C

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.


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. S263080

A

B

S261790

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

23 - 2

H

23 - 2

E

G

L L

C

E

F G

A

B

D S271860

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

23 - 3

23 - 3

Removal and Replacement Stabiliser Ram (Sideshift) Removal

Replacement

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

Lower the stabiliser legs until the pads 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.

Use suitable lifting appliances to locate the stabiliser ram.

5

Remove circlips E and drive out top pivot pin F with spacing collars G.

After replacing or fitting the ram, connect the hydraulic pipes, make sure that the ram and leg operate freely and do not foul.

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.


8



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.


10

Using suitable lifting equipment, lift the ram clear.

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

24 - 1

24 - 1

Removal and Replacement Dipper Ram

A C

B D

B

D C

S266350

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

24 - 2

24 - 2

Removal and Replacement Dipper Ram Removal

Replacement

1





INT-3-1-11/1

2

Vent residual hydraulic pressure from the backhoe hoses by operating the backhoe controls back and forth several times.


Label and then remove the dipper ram hoses A. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.


* *

4

Fasten lifting straps to the dipper ram, make sure that the weight of the ram is supported by the sling.

5

Remove the pivot pin retaining nut B and bolt C, remove the pivot pin D.

6

Remove dipper ram.

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

25 - 1

25 - 1

Removal and Replacement Bucket Crowd Ram

B

C

A D C

D

B

S266360

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

25 - 2

25 - 2

Removal and Replacement Bucket Crowd Ram Removal

Replacement

1





INT-3-1-11/1

2



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.


4

*5 *6

Fasten lifting straps to the bucket crowd ram, make sure that the weight of the ram is supported by the sling. Remove the pivot pin retaining nut B and bolt C, remove the pivot pin D. Remove the bucket crowd ram.

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

26 - 1

26 - 1

Removal and Replacement Boom Ram

E B C G A

F H

D

S266370

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

26 - 2

26 - 2

Removal and Replacement Boom Ram Removal

1

Replacement


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.


6



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.



Label and then remove the boom ram hoses E. Plug and cap all open orifices to prevent loss of fluid and ingress of dirt.


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.

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

30 - 1

30 - 1

20

14 15 16

13

11 9

3 5

4

10

1

4

7

8

19

18 17

6

12 s263650

2 5 6

4

9

3

7

1

11 10

TYPICAL RAM ASSEMBLY Note that on boom and bucket rams, pivot pin grease seals are fitted.

9803/3270

A263680

Issue 1

Section E

Hydraulics

Section E

Rams

30 - 2

Dismantling and Assembly - Loader Lift - Loader Shovel - Boom - Bucket - Stabilisers

30 - 2

When Assembling 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 old Loctite. Allow 15 minutes for solvent to dry before applying Loctite.

When Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling.

Ensure that lubricants used during assembly do not come into contact with Loctite. * Refer to the JCB Ram Sealing Procedure for the correct method of fitting seals to the end cap and piston head.

For assembly the sequence should be reversed. Place ram assembly on a locally manufactured strip/rebuild bench as shown.

Apply Loctite Activator T to threads of end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite. Note: Neither Loctite 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:

S263670

Slacken end cap 1 using special spanner (see Service Tools, Section 1) 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.

i

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.

ii

Remove all swarf and contamination. Insert dowel 6 into drilled hole, make sure tapped extractor hole is to outside.

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.

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 the piston rod. Follow the procedures 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.

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, Section 1). Remove gland bearing and end cap 1 from piston rod and remove the ‘O’ ring 9, wiper seal 10 and rod seal 11. 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.

i

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

Check the bore of the ram cylinder for damage.

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

30 - 3

30 - 3

Dismantling and Assembly: - Loader Lift - Loader Shovel - Boom - Bucket - Stabilisers DRILLING DETAILS FOR PISTON HEAD RETENTION When Assembling (continued)

X ii

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 5i.

iii

Use the correct size diameter drill to suit the dowel and drill to the required depth (see table).

iv

Remove all swarf and contamination, insert the dowel.

Position cylinder on bench and install rod assembly into cylinder. Apply Loctite 932 to first three threads of cylinder, torque tighten the end cap to 678 Nm (500 lbf ft). Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil. Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator T - 2 hours 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.

A263750

(all dimensions in mm) Ram Size

Dowel Size

Guide Drill Ø

Guide Drill Depth

Dowel Drill Ø X

Dowel Drill Depth Y

80 x 50 70 x 40

6Ø x 20

4

21

6.02/6.10

22/23

90 x 50 8Ø x 25 100 x 60

5

24

8.02/8.10

27/28

110 x 60 12Ø x 30 110 x 65

8

28

12.02/12.10 32/33

120 x 65 12Ø x 35 130 x 75

8

33

12.02/12.10 37/38

Torque Settings Item 7 1

Nm 405 678

9803/3270

kgf m 41.3 69.2

lbf ft 300 500

Issue 1

Section E

Hydraulics

Section E

Rams

31 - 1

31 - 1

19 20

14 13

22

3 5

8

1

11 12

21 9

10

4

6 7 18 16

17 15

S263740

2

7

6

5

4

3

8

11

12

1

14

13

S263730

9803/3270

Issue 1

Section E

Hydraulics

Section E

Rams

31 - 2

Dismantling and Assembly - Dipper Ram

31 - 2

When Assembling

When 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.

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 old Loctite. Allow 15 minutes for solvent to dry before applying Loctite. Ensure that lubricants used during assembly do not come into contact with Loctite. * Refer to the JCB Ram Sealing Procedure for the correct method of fitting seals to the end cap and piston head. Apply Loctite Activator T to threads of end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite. Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings, or 'O' rings.

S263670

Slacken end cap 1 using special spanner (see Service Tools, Section 1) 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.

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


2


3

New ram Shaft and piston head fitted. - If both are required, the following procedure should be followed:

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.

i


ii


Remove piston head from rod using special spanner (see Service Tools, Section 1).

4

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.


5


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.

...........continued

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

31 - 3

31 - 3

Dismantling and Assembly: - Dipper Ram When Assembling (continued) i 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. ii


iii


iv


DRILLING DETAILS FOR PISTON HEAD RETENTION

X

Y A263750

Position cylinder on bench and install rod assembly into cylinder.

(all dimensions in mm)

Apply Loctite 932 to first three threads of cylinder, torque tighten the end cap to 678 Nm (500 lbf ft).

Ram Size

Dowel Size

80 x 50 70 x 40

Guide Drill Ø

Guide Drill Depth

Dowel Drill Ø X

Dowel Drill Depth Y

6Ø x 20

4

21

6.02/6.10

22/23

90 x 50 8Ø x 25 100 x 60

5

24

8.02/8.10

27/28

Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator T - 2 hours

110 x 60 12Ø x 30 110 x 65

8

28

12.02/12.10 32/33

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.

120 x 65 12Ø x 35 130 x 75

8

33

12.02/12.10 37/38

Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil.

Torque Settings Item 7 1

Nm 405 678

9803/3270

kgf m 41.3 69.2

lbf ft 300 500

Issue 1

Section E

Hydraulics

Section E

Rams

32 - 1

32 - 1

2

3

4 5

1

6

10

9 8

7

11 12 16 15

14 13A

19

13

20 17

18 S263690

15

22

16 14

21

13

2 12 6

9803/3270

9

8

7

S263710

Issue 1

Section E

Hydraulics

Section E

Rams

32 - 2

Dismantling and Assembly - Slew Ram

32 - 2

When Assembling

When 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, Section 1). 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.

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 old Loctite. Allow 15 minutes for solvent to dry before applying Loctite. Ensure that lubricants used during assembly do not come into contact with Loctite. * Refer to the JCB Ram Sealing Procedure for the correct method of fitting seals to the end cap and piston head. Apply Loctite Activator T to threads of end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with Loctite. Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings, or 'O' rings. Fit locking dowel 10 to piston head/rod as follows: 1


2


3

New ram Shaft and piston head fitted. - If both are required, the following procedure should be followed: i


ii


S266380

4


5


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, Section 1). 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.

i

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

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. 9803/3270

Issue 2*

Section E

Hydraulics

Section E

Rams

32 - 3

32 - 3

Dismantling and Assembly - Slew Ram DRILLING DETAILS FOR PISTON HEAD RETENTION When Assembling (continued) ii


iii


iv


X

Y

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 Loctite 932 to first three threads of cylinder, torque tighten the cylinder to 678 Nm (500 lbf ft). Note: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil. Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator T - 2 hours 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.

A263750

(all dimensions in mm) Ram Size

Dowel Size

Guide Drill Ø

Guide Drill Depth

Dowel Drill Ø X

Dowel Drill Depth Y

80 x 50 70 x 40

6Ø x 20

4

21

6.02/6.10

22/23

90 x 50 8Ø x 25 100 x 60

5

24

8.02/8.10

27/28

110 x 60 12Ø x 30 110 x 65

8

28

12.02/12.10 32/33

120 x 65 12Ø x 35 130 x 75

8

33

12.02/12.10 37/38

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 kgf m 11 405 41.3 6 678 69.2

9803/3270

lbf ft 300 500

Issue 2

Section E

Hydraulics

Section E 33 - 1

Rams

33 - 1

A 1 A258580

4 5

B

7 6 8

8

A258590

2

D

3

2

C

7 8

1 8 6 4 5 1 4

6 8

322580

7

8

2

3

2

5 A326710

9803/3270

Issue 1

Section E 33 - 2

Hydraulics

Section E 33 - 2

Rams

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. When Dismantling Fix the ram assembly on a locally manufactured strip/rebuild bench as shown at A. Remove both end caps 1, (46mm AF). Pull the piston rod assembly from the cylinder. Note: DO NOT allow the piston rod to come into contact with the cylinder bore. The cylinder bore may be damaged by careless dismantling. 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. The piston head cannot be removed from the rod. If there is damage to the rod or piston head, replace the complete assembly. 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: If burrs are evident on the ends of the piston rod at positions C or D remove by careful filing. Remove the end cap seal 4, wiper seal 5 and ‘O’ ring 6, both end caps are the same Remove spacers 7 and ‘O’ rings 8. When Assembling Clean the threads of the end caps and cylinder using a wire brush. Use a JCB Cleaner & Degreaser to ensure that all threads are free from grease, hydraulic oil and Loctite. Allow 15 minutes for solvent to dry before applying Loctite.

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. Fit new ‘O’ rings 8 to spacers 7, slide onto the piston head and rod assembly. Apply Loctite Activator N to threads of the end caps and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the Loctite. Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings or ‘O’ rings. Apply Loctite 932 to threads of the ends caps, fit new ‘O’ rings 6. Ensure that there are no burrs at the ends of the piston rod, see Dismantling. 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: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20°C and are the minimum periods between assembly and filling the ram with oil. Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator Y - 2 hours Torque Settings Item 1

Nm 400

kgf m 40.8

lbf ft 295

Ensure that lubricants used during assembly do not come into contact with Loctite. * Refer to the JCB Ram Sealing Procedure for the correct method of fitting seals to the end cap and piston head.

9803/3270

Issue 2*

Section E 40 - 1

Hydraulics

Section E

Rams

40 - 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.

A

B

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.

D

C

Note: Later ram end caps and piston heads have metric threads. The seals are also different, make sure the correct seals are fitted. On metric threaded rams 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.

161750

P

Q

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.

153212

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, Section 1. Make sure the hexagon on the end cap is towards the eye end of the rod.

E A187361

9803/3270

Issue 1

Section E

Hydraulics

40 - 2 * JCB

Section E

Rams

40 - 2

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.

F G 338470

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.

H 338480

J

K

L 338490

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Hydraulic Oil Cooler

45 - 1

Hydraulic Oil Cooler 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.

45 - 1


! WARNING

GEN 3-2


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-3-1-11/1

INT-3-1-10/1

Removal

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).

1


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 orifices 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.

F

C A

E

D B

9803/3270

S266190

Issue 1

Section E

Hydraulics

Section E

Smooth Ride System

50 - 1

50 - 1

Technical Data Gas

Air Free Dry Nitrogen

* Accumulator Charge Pressure

3CX, 214, 215

GP Buckets without forks except 1.2m3 (1.5yd3) 96 inch GP Buckets with forks and 1.2m3 (1.5yd3) 96 inch without forks All Multipurpose Buckets except 1.3m3 (1.6yd3) Multipurpose Bucket 1.3m3 (1.6yd3)

13.75 bar (200 lbf/in2) 19 bar (275 lbf/in2) 24 bar (350 lbf/in2) 24 bar (350 lbf/in2)

4CX, 3CX Super, 214S, 215S, 217, 217S 13.75 bar (200 lbf/in2) 13.75 bar (200 lbf/in2) 19 bar (275 lbf/in2) 24 bar (350 lbf/in2)

As a general guide for given attachment weights see the table below: 3CX, 214, 215 up to 500 kg 500 to 700 kg (1100 lb) (1100 - 1540 lb) 13.75 bar 19 bar (200 lbf/in2) (275 lbf/in2)

over 700 Kg (1540 lb) 24 bar (350 lbf/in2)

4CX, 3CX Super, 214S, 215S, 217, 217S up to 700 kg 700 to 950 kg over 950 Kg (1540 lb) (1540 - 2100 lb) (2100 lb) 13.75 bar 19 bar 24 bar (200 lbf/in2) (275 lbf/in2) (350 lbf/in2)

Note: Replacement accumulators will only be supplied in an uncharged, non pressurised condition to meet Health and Safety/Airfreight hazardous goods requirements. Capacity

1.0 litre, 58 in3

Weight

4.4 Kg, 9.75 lb

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Smooth Ride System

50 - 2

50 - 2

Description Smooth Ride System (SRS) will enhance the 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 loader arms 1 to a pressurised piston type accumulator 2.

1

1

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. The smooth ride system will not function on machines fitted with hose burst check valves. For electrical diagram see Smooth Ride System, Section C.

4

3

4

2 1

T

1

P1

P2

T

ACC

3

2

A308380

9803/3270

Issue 1

Section E 51 - 1

Hydraulics

Section E

Smooth Ride System

51 - 1

Fault Finding Fault

Probable Cause

Action

1

Unable to power down loader arms with system switched OFF.

Rod side solenoid valve open.

Check if solenoid operating, replace solenoid or selector valve as required.

2

Restricted loader arm suspension movement when switched ON.

Rod side solenoid valve closed.


3

Springy loader arm lift with system switched OFF.

Head side solenoid valve open.


4

No suspension, unable to power down when switched ON.

Head side solenoid valve closed.


5

Accumulator gas pressure decrease.

Leak across accumulator piston.

Recharge, if frequent replace seals in accumulator.

6

Oil in gas side of 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.

9803/3270

Issue 1

Section E

Hydraulics

Section E

Smooth Ride System

52 - 1

52 - 1

Accumulator Charging

*1

Discharging

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.

*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.

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 (part no. 892/00948) to accumulator gas valve.

3

Screw T handle C all the way out (counter clockwise) before attaching charging tool (part no. 892/00948) to accumulator gas valve.

4

Close bleed valve D.

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).

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

Connect charging tool to a bottle of compressed nitrogen gas.

6

Screw T handle C all the way in (clockwise), this will depress the core in the gas valve.

*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 pressures see Technical Data, page E/50-1.

7

Open bleed valve D until all the gas charge is relieved from the accumulator. Remove the charging tool.

8

If charge pressure is low, release hand valve E on the nitrogen bottle and SLOWLY fill the accumulator. Close valve E when the 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, loose nut and remove charging tool.

12

Refit gas valve cap and valve guard.

A B

D

F

E

C

S308270

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Smooth Ride System

52 - 2

52 - 2

Accumulator Removal

Replacement

1

Replacement is a reverse of removal.

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.

Charge the system as detailed on page E/52-1. Check for correct operation and leaks. Replenish the hydraulic system with the recommended hydraulic fluid as required.

Hyd 2-5

2

Discharge the accumulator as detailed on page E/52-1.

3

Disconnect hydraulic pipe A and plug.

* Note: On later machines hydraulic pipe A has been changed to a hydraulic hose. 4

Loosen both ‘U’ clamps B slide the accumulator towards the front of the machine, lower the rear when clear of ‘U’ clamp and withdraw accumulator.

A B

B S308290

9803/3270

Issue 2*

Section E

Hydraulics

Section E

Smooth Ride System

52 - 3

10

9

52 - 3

10

8

7

A 7

8 7

1 A 7

5 7 8 6 11 10 9 10

11 8 7 4 13

12 3 2

9803/3270

S308280

Issue 1

Section E

Hydraulics

Section E

Smooth Ride System

52 - 4

52 - 4

Accumulator Dismantle

Assembly

! 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.

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.

HYD 2-5

1

Check that the accumulator has been discharged, see page E/52-1.

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.

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. 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.

HYD 2-6

4

Fit three pins into the holes in gas end cap 4, using a long bar working against the pins unscrew the end cap.

5

Fit three pins into the holes in hydraulic end cap 5, using a long bar working against the pins unscrew the end cap.

6

6

Remove and discard ‘O’ rings and back up rings from end caps.

Note: The end caps will stop against the chamfer leading into the honed bore, ‘O’ ring sealing is not dependent upon cap tightness.

7

Remove the piston 6 by pushing from the hydraulic end with a bar.

7

Use new ‘O’ ring 13 and fit the gas valve 12.

! CAUTION

Do not remove the piston by applying compressed air at the opposite end. HYD 2-7

8

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.

9803/3270

Issue 1

Section F

Transmission

Section F

i

i

Contents

1-7 1-8 1-9 1 - 10 1 - 11

Towing Procedure Syncro Shuttle Gearbox Powershift Gearbox

1 - 12 1 - 12

1-1 1-1 1-1 1-2 1-2 1-3 1-4 1-5 1-6

Summary of Changes

2-1

Propshafts Removal and Replacement

3-1

Front Axle - SD55/SD70 Torque Figures and Cut-a-way of Front Axle Removal and Replacement Renewing the Pinion Oil Seal Hub and Driveshaft - Dismantling - Assembly Drivehead (4WS Machines) - Dismantling - Assembly Drivehead (2WS Machines) - Dismantling - Assembly Removal and Replacement (2 Wheel Drive Machines) Dismantling and Assembly (2 Wheel Drive Machines) Rear Axle Torque Figures and Cut-a-way of Rear Axle Removal and Replacement Renewing the Pinion Oil Seal Brakes (without controlled back off) - Dismantling - Assembly * Brakes (with controlled back off) - Dismantling - Assembly

9803/3270

Page No.

Technical Data Front axle - All Wheel Steer Machines - 2 Wheel Steer Machines - 2 Wheel Steer (2 Wheel Drive) Machines Rear Axle - All Wheel Steer Machines - 2 Wheel Steer Machines Tyre Pressures - Front Wheels - Rear Wheels Syncro Shuttle Transmission Powershift Transmission Pump/Transmission Stall Speed Combinations - 2 Wheel Steer Machines, Gear Pump - All Wheel Steer Machines, Gear Pump - All Wheel Steer Machines, Variable Pump - Low Emission Engine, 2 Wheel Steer Machines - Low Emission Engine, All Wheel Steer Machines

20 - 1 21 - 1 22 - 1 23 - 1 23 - 6 24 - 1 24 - 3 25 - 1 25 - 2 26 - 1 27 - 1

40 - 1 41 - 1 42 - 1 43 - 1 43 - 3 43 - 4 43 - 6

Issue 5*

Section F

Transmission

Section F

ii

ii

Contents Hub and Driveshaft SD70 - Doweled Hub - Dismantling - Doweled Hub - Assembly Hub and Driveshaft PD70 - Dismantling - Assembly Hub and Driveshaft SD70 - Splined Hub - Dismantling - Splined Hub - Assembly Drivehead - Dismantling - Assembly Limited Slip Differential Dismantling and Assembly

44 - 1 44 - 3 44 - 5 44 - 5 44 - 6 44 - 8 45 - 1 45 - 4 46 - 1

Syncro Shuttle Transmission General Description and Operation Synchromesh Operation Clutch Operation 4 Wheel Drive Operation 2 Wheel Drive Operation Fault Finding - Syncro Shuttle Gearbox - 2/4 Wheel Drive Clutch Removal and Replacement Sectional Views and Torque Figures Gearbox - Dismantling Gearbox - Assembly Polytetrafluorethylene (PTFE) Piston Ring Seals - Fitting Procedure Solenoid Valve - Dismantling and Assembly Reverser Unit - Dismantling Reverser Unit - Assembly Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON) - Dismantling and Assembly Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON) - Dismantling and Assembly Torque Converter - Removal and Replacement - Stall Test - Pressure and Flow Test

69 - 1 70 - 1 70 - 2

Collapsible Spacer - Assembly Output Shaft (Larger Diameter Gear)

80 - 1 80 - 2

Powershift Transmission General Descriptions Hydraulic Operation Drivepaths Clutch Operation 2/4 Wheel Drive Operation Fault Finding - Transmission - 2/4 Wheel Drive Clutch Removal and Replacement

9803/3270

Page No.

60 - 1 60 - 3 60 - 5 60 - 6 60 - 6 61 - 1 61 - 4 62 - 1 63 - 1 64 - 1 64 - 7 65 - 1 66 - 1 67 - 1 67 - 3 68 - 1 68 - 4

100 - 1 100 - 3 100 - 5 100 - 8 100 - 8 101 - 1 101 - 4 102 - 1

Issue 6

Section F

Transmission

Section F

iii

iii

Contents

Page No.

PS700 Sectional Views and Torque Figures 103 - 1 Dismantling (See Summary of Changes) 104 - 1 Assembly (See Summary of Changes) 104 - 6 Polytetrafluorethylene (PTFE) Piston Ring Seals - Fitting Procedure 105 - 1 Solenoid Valve - Dismantling and Assembly 106 - 1 PS700 Input Clutch and Reverser Clutch - Dismantling 107 - 1 PS700 Input Clutch and Reverser Clutch - Assembly 107 - 3 PS750 Input Clutch and Reverser Clutch - Dismantling 107 - 5 PS750 Input Clutch and Reverser Clutch - Assembly 107 - 7 PS700 Mainshaft - Dismantling 108 - 1 PS700 Mainshaft - Assembly 108 - 3 PS750 Mainshaft - Dismantling 108 - 5 PS750 Mainshaft - Assembly 108 - 7 PS700 Layshaft - Dismantling 109 - 1 PS700 Layshaft -- Assembly 109 - 4 PS750 Layshaft - Dismantling 109 - 8 PS750 Layshaft -- Assembly 109 - 10 Hydraulic 2/4 Wheel Drive Unit - Dismantling and Assembly 110 - 1 Torque Converter - Removal and Replacement 110 - 1 Torque Converter Stall Test 111 - 1 Testing for Clutch Leakage 111 - 2 Pressure and Flow Testing 111 - 4 Flushing the Transmission Oil 112 - 1 Powershift (With Reverser Shaft Sealing Plug & PS750), (See Summary of Changes) PS750 Sectional Views and Torque Figures 119 - 1 Dismantling 120 - 1 Assembly 121 - 1

9803/3270

Issue 4

Section F

Transmission Technical Data

1-1

Section F 1-1

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 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 2 WHEEL STEER MACHINES (2 Wheel Drive) Type Installation Weight (dry, with steer ram and without wheels) Oscillation Toe - in Castor Angle Camber Angle

9803/3270

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°

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 OPTION 2 16.2:1 19.2:1 3:1 3.556:1 33 11

32 9

JCB centre oscillation, non-driven Centre pivot 239 kg (525 lbs) approximately ± 5° 0° 0° 3 ° positive

Issue 1

Section F

Transmission

Section F

Technical Data

1-2

1-2

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

3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking SD70 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 OPTION 2 15.78:1 18.16:1 2.923:1 3.363:1

OPTION 3 13.7:1 2.538:1

38 13

33 13

37 11

* Note: From 1st April 1999 the hub is splined and not doweled. Machine serial number TBA. 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

9803/3270

3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking PD70 Rigid pad mount 386 kg (851 lbs) approx. 5 friction plate, 6 counter plate (each half shaft) Yoke 5.4:1 OPTION 1 OPTION 2 OPTION 3 15.78:1 18.16:1 13.7:1 2.923:1 3.363:1 2.538:1 38 13

37 11

33 13

Issue 2*

Section F

Transmission

Section F

Technical Data

1-3

1-3

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

Remarks

Pressure bar

lbf/in2

1

16.9x24x12

IND

ARMSTRONG

TUBELESS

2.6

38

2

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

38

3

15.5x25

XTLA

MICHELIN

TUBELESS

2.5

36

4

16.9x28x12

IND

ARMSTRONG

TUBELESS

2.6

38

5

16.9x28x12

IND

GOODYEAR

TUBELESS

2.6

38

6

16.9x28x10

IND

GOODYEAR

TUBELESS

2.2

32

7

16.9x28

XM27

MICHELIN

TUBELESS

2.7

39

8

16.9x28x14

IND

NOKIA

TUBE

2.6

38

9

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

38

10

16.9x28x12

TRAC

OLYMPIC

TUBELESS

2.6

38

11

16.9x28x12

IND

OLYMPIC

TUBE

2.6

38

12

14.9x24x12

IND

GOODYEAR

TUBELESS

2.75

40

13

16.9x28

IND

GOODYEAR

TUBELESS

2.5

36

2WS/2WD MACHINES 21

11.0x16x12

RIB

ARMSTRONG

TUBELESS

4.4

64

22

11.0x16x12

RIB

GOODYEAR

TUBELESS

4.2

61

23

11Lx16x12

IND

ARMSTRONG

TUBELESS

4.4

64

24

10.5x18x10

IND

FIRESTONE

TUBELESS

3.8

55

25

12.0x18x12

IND

FIRESTONE

TUBELESS

3.5

51

2WS/4WD MACHINES 31

14x17.5x10

IND

ARMSTRONG

TUBELESS

3.8

55

32

14x17.5x10

IND

GOODYEAR

TUBELESS

3.8

55

34

12.0x18x12

IND

FIRESTONE

TUBELESS

3.5

51

35

12.0x18x12

IND

OLYMPIC

TUBELESS

4.25

62

36

335 x18

XM27

MICHELIN

TUBELESS

3.5

51

37

12.5x18x10

IND

GOODYEAR

TUBELESS

4.25

62

38

335 x20

XM27

MICHELIN

TUBE

3.0

43.5

39

340 x18

IND

GOODYEAR

TUBELESS

3.2

46

Items 4, 5, 6, 7,8, 9, 10, 11, 13, 38 must have steering lock restriction stops fitted.

9803/3270

Issue 1

Section F

Transmission

Section F

Technical Data

1-4

1-4

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

Remarks

Pressure bar

lbf/in2

1

16.9x24x12

IND

ARMSTRONG

TUBELESS

2.6

38

2

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

38

3

15.5x25

XTLA

MICHELIN

TUBELESS

2.5

36

4

16.9x28x12

IND

ARMSTRONG

TUBELESS

2.6

38

5

16.9x28x12

IND

GOODYEAR

TUBELESS

2.6

38

6

16.9x28x10

IND

GOODYEAR

TUBELESS

2.2

32

7

16.9x28

XM27

MICHELIN

TUBELESS

2.7

39

8

16.9x28x14

IND

NOKIA

TUBE

2.6

38

9

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

38

10

16.9x28x12

TRAC

OLYMPIC

TUBELESS

2.6

38

11

16.9x28x12

IND

OLYMPIC

TUBE

2.6

38

12

14.9x24x12

IND

GOODYEAR

TUBELESS

2.75

40

13

16.9x28

IND

GOODYEAR

TUBELESS

2.5

36

2WS MACHINES 21

16.9x24x10

IND

ARMSTR0NG

TUBELESS

2.2

32

22

16.9x24x12

IND

GOOOYEAR

TUBELESS

2.2

32

23

19.5x24x10

IND

ARMSTRONG

TUBELESS

1.9

28

24

19.5x24x12

IND

ARMSTRONG

TUBELESS

2.3

33

25

21L x24x12

IND

GOODYEAR

TUBELESS

2.2

32

26

18.4x26x12

TRAC

GOODYEAR

TUBELESS

2.5

36

* 27

18.4x26x12

TRAC

OLYMPIC

TUBELESS

2.4

35

28

18.4x26x12

IND

GOODYEAR

TUBELESS

2.0

29

29

16.9x28x12

TRAC

OLYMPIC

TUBELESS

2.2

32

30

16.9x28x12

TRAC

FIRESTONE

TUBE

2.2

32

31

16.9x28x12

IND

GOODYEAR

TUBELESS

2.2

32

32

16.9x28

XM27

MICHELIN

TUBELESS

2.5

36

33

18.4x30x14

IND

GOODYEAR

TUBE

2.0

29

34

16.9x28

IND

GOODYEAR

TUBELESS

2.5

36

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.

9803/3270

Issue 2*

Section F

Transmission

Section F

Technical Data

1-5

1-5

Syncro Shuttle Description Designation Weight (dry) 2WD 4WD Gear Ratios 1st 2nd 3rd 4th Torque Convertor Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Convertor Colour Coded Dots

Combined torque converter, reverser, and gearbox unit with integral parking brake. SS640 (4 wheel drive) 157 kg (346 lb) 176 kg (388 lb) Std Ratio Low Ratio 5.56:1 6.56:1 3.45:1 4.06:1 1.83:1 1.90:1 1.00:1 1.00:1 310 mm (12.2 in.) 12.2 - D 12.2 - P 2.82:1 2 Purple 2 Orange 1 Yellow 1 Yellow

2.54:1

Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min Converter In at 100 deg.C 1000 rev/min 2000 rev/min Converter Out at 50 deg.C 1000 rev/min 2000 rev/min Converter Out at 100 deg.C 1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.)

bar 2.4 - 3.4 5.2 - 6.5 1.3 - 2.0 5.2 - 5.9 1.0 - 1.7 2.0 max 0.3 - 0.6 1.0 - 1.7 6.5

kgf/cm2 2.5 - 3.5 5.3 - 6.7 1.4 - 2.1 5.3 - 6.0 1.1 - 1.8 2.0 max 0.3 - 0.6 1.1 - 1.8 6.7

Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min

bar 0.2 - 0.3 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6

kgf/cm2 0.2 - 0.4 0.4 - 0.7 0.1 - 0.2 0.3 - 0.6

lbf/in2 3.0 - 5.0 6.0 - 10.0 2.0 - 3.0 4.0 - 8.0

Main Line Pressure (in neutral) † At 50 deg. C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min

bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4

kgf/cm2 9.8 - 13.0 11.6 - 14.4 11.6 - 13.0 11.6 - 13.7

lbf/in2 140 - 185 165 - 205 165 - 185 165 - 195

Clutch Pressures † Flow Rates (in neutral) Cooler at 50 deg.C Cooler at 100 deg.C Pump at 50 deg.C

lbf/in2 35 - 50 75 - 95 20 - 30 75 - 85 15 - 25 29 max 4.0 - 8.0 15 - 25 95

All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)

1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

L/min 10.4 - 13.6 14.5 - 20.0 10.2 - 12.5 22.7 - 26.1 11.0 - 15.0 22.5 - 29.5

US gal/min 2.8 - 3.6 3.8 - 5.3 2.7 - 3.3 6.0 - 6.9 2.9 - 4.0 6.0 - 7.8

UK gal/min 2.3 - 3.0 3.2 - 4.4 2.3 - 2.8 5.0 - 5.7 2.5 - 3.3 5.0 - 6.5

† Note: For gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).

9803/3270

Issue 1

Section F

Transmission

Section F

Technical Data

1-6

1-6

Powershift Description

Designation Weight (dry) 2WD 4WD Gear Ratios 1st 2nd 3rd 4th Torque Convertor Torque Converter Dia. Torque Converter Identification Torque Multiplication at Stall Torque Convertor Colour Coded Dots

Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs. Torque converter and parking brake integral . PS740 (4 wheel drive) and PS750 220 kg (484 lb) 236 kg (519 lb) Std Ratio 5.72:1 3.23:1 1.77:1 1.00:1

Low Ratio 6.58:1 3.71:1 1.77:1 1.00:1

310 mm (12.2 in.) 12.2 - D 12.2 - P 2.82:1 2 Purple 2 Orange 1 Yellow 1 Yellow bar kgf/cm2 2.8 - 4.1 2.8 - 4.2 4.8 - 6.2 4.9 - 6.3

lbf/in2 40 - 60 70 - 90

Converter Out at 50 deg.C

1000 rev/min 2000 rev/min Converter Inlet Relief Valve Pressure (max.)

1.9 - 2.3 2.3 - 2.7 6.5

1.9 - 2.3 2.3 - 2.7 6.7

27 - 33 33 - 39 95

Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min

bar 0.14 - 0.28 0.28 - 0.55

kgf/cm2 0.14 - 0.28 0.28 - 0.56

lbf/in2 2.0 - 4.0 4.0 - 8.0

Main Line Pressure (in neutral) † At 50 deg. C 1000 rev/min 2000 rev/min At 100 deg.C 1000 rev/min 2000 rev/min

bar 9.7 - 12.8 11.4 - 14.1 11.4 - 12.8 11.4 - 13.4

kgf/cm2 9.8 - 13.0 11.6 - 14.4 11.6 - 13.0 11.6 - 13.7

lbf/in2 140 - 185 165 - 205 165 - 185 165 - 195

Converter Pressures (in neutral) Converter In at 50 deg.C 1000 rev/min 2000 rev/min

Clutch Pressures † Flow Rates (in neutral) Cooler at 50 deg.C Pump at 50 deg.C

2.54:1

All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2)

1000 rev/min 2000 rev/min 1000 rev/min 2000 rev/min

litres/min 10.4 - 13.6 14.5 - 20.0 11.0 - 15.0 22.5 - 29.5

US gal/min 2.8 - 3.6 3.8 - 5.3 2.9 - 4.0 6.0 - 7.8

UK gal/min 2.3 - 3.0 3.2 - 4.4 2.5 - 3.3 5.0 - 6.5

† Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).

* Stall

Speed Combinations

The stall speed figures on the following pages were conducted at an ambient of 25 deg. C and barometric pressure of 100 kPa (sea level). Changes in ambient temperature, pressure and humidity will affect engine power and hence 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%.

9803/3270

Issue 3*

9803/3270

● ● ● ● ●

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●

●

●

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1720 1580

2220 2160

214T/215E N. Am.

●

●

●

●

●

1630 1540

2070 1975

●

●

●

1620 1540

2060 1960

215/217 215/217 N. Am. N. Am.

●

● ●

●

●

●

●

●

1745 1620

2230 2170

214T/215E N. Am.

Transmission

● ●

●

●

●

●

●

1650 1575

2200 2095

214 N. Am.

Air Conditioning None (Europe) None (R.O.W.) Europe Europe (Hot) R.O.W.

●

●

●

●

●

1345 1140

2160 2050

214E N. Am.

●

●

● ●

●

●

1635 1545

2070 1980

3CXT

Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16

Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc

●

●

●

●

●

1655 1560

2100 2000

3CXT

1-7

●

●

1445 1270

2015 1910

3CXT

Convertor type. 12.2D (2.82) 12.2P (2.54)

●

1475 1310

2040 1935

3CXT

●

●

1550 1405

2015 1910

3CXT

Build specification. Engine size. N.A. (75hp) (56kw) T2 (91hp) (68kw) T3 (96hp) (72kw)

●

1575 1430

2.Convertor + M.R.V. Max.r.p.m. Min.r.p.m.

1465 1365

2040 1935

Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 1880 1905 Min.r.p.m. 1790 1800

1100 stall

3CXT

3CX

3CXE

Note. On all double pump options the test is to be carried out with single pump option selected.

Pump/Transmission Stall Speed Combinations - Two wheel steer machines, 12.2 convertor, gear pump, 1000 series engine

Section F Section F

Technical Data 1-7

Issue 1

9803/3270

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1620 1530

2060 1960

4C/4CN

●

●

●

●

●

1655 1560

2100 2000

214S N. Am.

●

●

●

●

●

1635 1545

2075 1980

214S N. Am.

●

●

●

●

1620 1530

2060 1960

215S/217S N. Am.

Technical Data

●

●

●

●

●

●

1630 1540

2070 1975

215S/217S N. Am.

Transmission

● ● ●

●

●

●

●

1630 1540

2070 1975

4C/4CN


●

●

●

●

1650 1560

2095 2000

4C/4CN

●

●

●

●

●

1635 1545

2070 1980

4CX

Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16


●

●

Convertor type 12.2D (2.82) 12.2P (2.54)

●

●

●


1655 1560

2100 2000

4CX

1-8

●

1550 1405


1575 1430

2015 1910

3CXSuper

Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 2040 Min.r.p.m. 1935

3CXSuper


Pump/Transmission Stall Speed Combinations - All wheel steer machines, 12.2 convertor, gear pump, 1000 series engine

Section F Section F 1-8

Issue 1

9803/3270

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2155 2020

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2130 2035


●

●

●

●

2155 2055

4CXSuper 4CXSuper 4CXSuper

●

●

Pump size. 74 Variable

●

●


●

2130 2035

4CX

1-9

Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16

●



4CX

Pump/Transmission Stall Speed Combinations - All wheel steer machines, 12.2 convertor, variable pump, 1000 series engine

Section F Transmission Section F

Technical Data 1-9

Issue 2

9803/3270

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Transmission

●

●

●

●

●

1760 1645

2120 2015

Air Conditioning None Europe ROW

●

●

●

●

●

●

●

1875 1745

2230 2160

215 217 N. Am.

●

●

●

●

●

●

1890 1760

2240 2165

215E 214T N. Am.

●

●

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1745 1580

2240 2170

215E 214T N. Am.

●

●

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●

●

1770 1625

2220 2110

N. Am.

214e.T

Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16

●

●

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1555 1280

2240 2170

N. Am.

214

●

●

●

●

●

1415 stall

2170 2075

N. Am.

214e


●

●

●

●

1760 1650

2125 2020

N. Am.

214E

1 - 10

●

●

1770 1660

2135 2030

Convertor type. SSL11(2.83) 12.2D (2.82) 12.2P (2.54)

●

1660 1530

2070 1965

3CX

Contractor Contractor

3CX

●

●

1675 1545

2080 1980

Hi. lift

3CXT

Build specification. Engine size. N.A. (75hp) (56kw) T1 (80hp (60kw) T2 (91hp) (68kw) T3 (100hp) (74kw)

●

1720 1600

1735 1615


1520 1380

2070 1960

Std lift Hi. lift

Std lift

3CXT

3CXT

3CXT

Engine Speed @ Stall Combination 1.Convertor only. Max.r.p.m. 1965 2080 Min.r.p.m. 1850 1975

3CX


*Low Emission Engine Stall Speed Combinations - Two wheel steer machines

Section F Section F

Technical Data 1 - 10

Issue 2*

9803/3270

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1760 1645

2120 2015

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2180 2080

4CXS 4CX

●

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2170 2065

4CXS 4CX

●

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1760 1645

2120 2015

215S/217S N. Am.

●

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1760 1650

2125 2020

214S N. Am.

Technical Data

●

●

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1770 1660

2135 2030

4CXS/4C 4CXS/4C

Transmission

●

Air Conditioning None (Europe) None Europe Europe (Hot) R.O.W.

●

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●

●

Fan Ratio. 1 to 0.85 1 to 1.06 1 to 1.16

Pump size. 50cc 33/23cc 36/26cc 41/26cc 41/29cc 74 Variable

●

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1760 1650

2125 2020

4CX

1 - 11

●

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1770 1660

2135 2030

4CX


●

1660 1530

2070 1965

3CXS Hi. lift

●

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1675 1545

2080 1980

3CXS Hi. lift


●

1720 1600


1735 1615

2070 1965

3CXS Std lift


3CXS Std lift


*Low Emission Engine Stall Speed Combinations - All wheel steer machines

Section F Section F 1 - 11

Issue 1

Section F 1 - 12

Transmission

Section F

Towing Procedure

1 - 12

Syncro Shuttle & Powershift Gearbox If there is no transmission damage, the machine may be towed for a distance of approximately 1.5 kilometres (1 mile). Always use a rigid tow bar, ensure that the gear lever is in neutral (applicable to Syncro Shuttle machines only). Restrict towing speed to 25 k.p.h. (15 m.p.h.). If it is necessary to tow the machine for a distance in excess of 1.5 kilometres (1 mile) the propshafts should be disconnected to prevent damage to the transmission system.

! WARNING When the rear propshaft is disconnected the parking brake will not function. It is essential that the following procedure be adopted. TRAN 1-5

Position the machine on firm level ground and block the wheels securely to prevent any movement. Select neutral (Syncro Shuttle machines only) and release the parking brake. Disconnect the rear propshaft from the axle, and tie up the shaft securely well clear of the rotating axle yoke. Alternatively remove the shaft completely. Connect the towing vehicle via the towbar BEFORE removing the blocks from the wheels. Restrict the towing speed to 25 k.p.h. (15 m.p.h.). When towing is complete, block the wheels securely BEFORE removing the towbar and reconnecting the propshafts. Important: In some countries neither of the above procedures may be legally acceptable for towing on public highways.

9803/3270

Issue 1

Section F

Transmission Powershift

2-1

Section F 2-1

Summary of Changes 1

Reverser Shaft Clutch Pack Sealing Plug The casing on the transmission has been altered, while the casings are interchangeable the Dismantling and Assembly procedures differ. Both procedures are included in this manual, use Figs. A and B to identify the procedure required to service your transmission.

Fig A:

The reverser clutch pack shaft end float and shimming is carried out through an access port in the front casing which is sealed by a cover plate and gasket.

Fig B:

The reverser clutch pack shaft end float check is carried out through the reduced opening, the casings are then separated and shimmed on the inside.

A

B

Powershift PS700 only.

S217380

*2

Powershift with reverser shaft sealing plug & PS750.

A311480

Introduction of Powershift 750 (PS750) The Dismantling and Assembly procedure for PS750 is the same as the ‘Powershift With Reverser Sealing Plug’ procedure. The procedures for the PS750 clutch packs differ from the PS700 clutch packs but have been kept together in the Service Manual for simplicity, make sure you use the correct procedure.

9803/3270

Issue 2*

Section F

Transmission

Section F

Propshafts

3-1

3-1

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.

REAR

Apply JCB Lock and Seal 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

B

A

S157510

C X

A

S232350

Y A

A

Z

S157500 S189610

FRONT 9803/3270

Issue 1

9803/3270 A355950

Transmission Front Axle

Wheel Nuts 680 Nm; 69 kgf m; 500 lbf ft

Differential Case Bolts - JCB Threadocker & Sealer M/C Grade Torque 4WS 8.8 56 Nm; 5.7 kgf m; 42 lbf ft 2WS 8.8 28 Nm; 2.9 kgf m; 21 lbf ft 2WS 12.9 46 Nm; 4.7 kgf m; 34 lbf ft

Drain & Fill Plugs 79 Nm; 8 kgf m; 60 lbf ft

Crownwheel Retaining Bolts AWS M/c’s = 166 Nm; 16.9 kgf m; 122 lbf ft 2WS M/c’s = 94 Nm; 9.6 kgf m; 70 lbf ft

Planet Carrier Bolts (8.8)JCB Threadlocker & Sealer 56 Nm; 6 kgf m; 42 lbf ft

Trunnion Bolts JCB Threadlocker & Sealer 98 Nm; 10 kgf m; 72 lbf ft

20 - 1

Stake Nut See Renewing the Pinion Oil Seal

Propshaft Retaining Bolts (12.9) 79 Nm; 8 kgf m; 58 lbf ft

Drivehead Bolts - JCB Multi-Gasket Axle Bolt Grade Torque SD55 M10 8.8 56 Nm; 5.7 kgf m; 42 lbf ft SD55 M10 12.9 94 Nm; 9.6 kgf m; 70 lbf ft SD70, SD80 M12 8.8 98 Nm; 10 kgf m; 72 lbf ft SD70, SD80 M12 12.9 166 Nm; 17 kgf m; 122 lbf ft

Typical axle shown, torque figures apply to AWS and 2WS machines - differences are indicated in text. When appropriate, the grade of the bolt is indicated either in the text or in parenthesis, e.g. ‘(12.9)’. Refer also to relevant dismantling and assembly procedures.

Front Axle Torque Figures

Section F Section F 20 - 1

Issue 2

Section F

Transmission

Section F 21 - 1

Front Axle

21 - 1


K

C

-238.14

A

C D

J

B

H

F

B E G A258200

9803/3270

Issue 1

Section F


21 - 2

Section F 21 - 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.

9803/3270

Issue 1

Section F

Transmission

Section F 21 - 3

Front Axle

21 - 3

Removal and Replacement (cont’d) Replacement Replacement is the reverse of the removal sequence.

! WARNING

Y

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. 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.

X

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.

A258180

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, as described on page H/35-1. Torque Settings Item A D

Nm 79 680

9803/3270

kgf m 8 69

lbf ft 58 500

Issue 1

Section F

Transmission

Section F 22 - 1

Front Axle - SD55/SD70

22 - 1

Renewing the Pinion Oil Seal The pinion oil seal 3 may be renewed without removing the axle from the machine.

4

4.1 Using Service Tool 892/00812, tighten the nut to 200 Nm (148 lbf ft; 20.4 kgf m).

! 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

Remove the roadwheels and uncouple the axle propshaft. Measure the axle rolling torque and record the reading.

2

Using Service Tool 892/00812, remove the drive flange 1 together with its stake nut 2.

Fit the coupling yoke and a new stake nut:

4.2 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). 4.3 If necessary, progressively torque tighten nut to achieve 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, then the collapsible spacer mounted on the axle pinion MUST be renewed. 4.4 Stake the nut using a square ended staking tool.

3

5

Refit the roadwheels and couple the propshaft.

Remove the seal 3 and fit a new one. Pack between the lips of the new seal with grease before fitting.

Typical Axle Shown S242140

9803/3270

Issue 1

Section F

Transmission

Section F


23 - 1

23 - 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.


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

9803/3270

Issue 1

Section F 23 - 2

Transmission

Section F


23 - 2

Hub and Driveshaft - Dismantling (cont'd) 7

Remove circlip D to allow the sun gear to be slid off the drive shaft.

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

E

255930

11

Using 2 high grade M14 bolts as jacking screws, 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.

S258240

9803/3270

Issue 1

Section F 23 - 3

Transmission

Section F


23 - 3


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

X

A258390

9803/3270

Issue 1

Section F 23 - 4

Transmission

Section F


23 - 4


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 discard the combination seal. When assembling the axle, a new combination seal must be used.

S248880

17

Mark position of top and bottom trunnions H and remove. Withdraw the hub carrier.

H

Note 1: Trunnions may be removed easily by pumping grease through the grease nipple.

H 18

S248890

Use adaptor 993/59500 with slide hammer tool 892/00224 and remove driveshaft seal and needle roller bearing from the hub carrier.

S161460

9803/3270

Issue 1

Section F 23 - 5

Transmission

Section F


23 - 5


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.

K J

255990

9803/3270

Issue 1

Section F 23 - 6

Transmission

Section F


23 - 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.

K J 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

9803/3270

Issue 1

Section F 23 - 7

Transmission

Section F


23 - 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 Lock and Seal 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.

S248850

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.

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.

A

A267170

S248920

9803/3270

Issue 1

Section F

Transmission

Section F


23 - 8

23 - 8


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, page F/23 - 2, 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 page 1/4-11.

S248540

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. S248870

15

Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force - see step 16.

S248540

9803/3270

Issue 1

Section F

Transmission

Section F


23 - 9

23 - 9


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.

-

S248870

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.

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.

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.

D S258230

9803/3270

Issue 1

Section F 23 - 10

Transmission

Section F


23 - 10


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

9803/3270

Issue 1

Section F 24 - 1

Transmission

Section F 24 - 1

Front Axle - SD70

S161871

9803/3270

Issue 1 SXXXXXX

SXXXXXX

Section F 24 - 2

Transmission

Section F 24 - 2

Front Axle - SD70

Drivehead - Dismantling (4WS Machines) 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 driveshafts (see pages F/23-1 to F/23-10).

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 collapsible spacer 30 and taper roller bearing cone 31 from pinion 24.

with

9803/3270

Issue 1 SXXXXXX

SXXXXXX

SXXXXXX

Section F

Transmission

Section F 24 - 3

Front Axle - SD70

24 - 3

Drivehead - Assembly (4WS Machines) Pinion Depth Setting Procedure 1

Place new pinion inner bearing 31 and outer race 28 (see page F/24-1) on a flat surface and position bearing cup 892/00174 over the bearing assembly.

2

Measure gap A (e.g. 0.20mm) and add this to the cup depth stamped on the tool (e.g. 30.01mm) to obtain the bearing depth.

3

From the face of the pinion, obtain the etched deviation figure (e.g. + 2) which is in units of 0.01mm. If positive, add this to the bearing depth; if negative, subtract from the bearing depth.

4

Obtain the deviation figure (e.g. —1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

5

Subtract the total of the above figures from the standard value of 31.19mm. The result will be the thickness of shims required behind the pinion inner bearing outer race.

S184400

Example (all dimensions in millimeters) Cup Depth Gap A Bearing Depth Pinion Deviation (+ 2) Housing Deviation (—1)

30.01 + 0.20 30.21 + 0.02 + 0.01

Total

30.24

Standard Value Less Total From Above

31.19 30.24

Shim Thickness

0.95

Note: In rare instances, it is possible that the setting data stamp may be omitted from the drivehead casing. In these circumstances the following setting procedure should be used: Revise the shim pack size by the difference in setting height marked on the old and new crownwheel and pinion sets.

9803/3270

Issue 1 SXXXXXX

SXXXXXX

SXXXXXX

Section F 24 - 4

Transmission

Section F 24 - 4

Front Axle - SD70

S161871

9803/3270

Issue 1 SXXXXXX

SXXXXXX

Section F

Transmission

Section F 24 - 5

Front Axle - SD70

24 - 5

Drivehead - Assembly (4WS Machines) Note 1: The crownwheel 20 and pinion 24 are matched and should be renewed as a pair if either one is damaged or excessively worn. The two differential case halves 12 and 13 are also matched as are gears 14 and 16. Do not use unmatched halves or gears. Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set. 1

2

Fit to the drive head carrier 2 the pinion inner bearing outer race 28 together with the required thickness of shim(s) 29 to give correct pinion depth. (See Pinion Depth Setting Procedure, page F/24-3). Fit the shims behind the outer race as shown. Fit new taper roller bearing cone 31 and a new collapsible spacer 30 onto pinion 24.

3

Fit outer race 27 to the drive head carrier 2.

4

Insert the pinion 24 into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same).

5

6

Fit new taper roller bearing cone 26. Pack the cavity between the lips of the new oil seal 25 with grease and fit the seal to the drive head carrier 2.

9

Position top case half 12 onto bottom half assembly 13 aligning the match mark letters (see Note 1 opposite). Apply JCB Lock & Seal to the threads of bolts 11 then fit and torque tighten to 56 Nm (42 lbf ft; 6 kgf m). Check the gears for free rotation.

10

Press taper roller bearing cone 18 onto the spigot of case half 12.

11

Install the differential assembly 10 into the drive head carrier 2.

12

Press taper roller bearing cone 9 onto the spigot of case half 13.

13

Fit bearing outer races 7 and 8, castellated nuts 5 and 6 to the drive head carrier 2.

14

Adjust castellated nuts 5 and 6 to give a bearing preload (see Note 2) of 1.36 to 2.5 Nm (1.0 to 1.84 lbf ft; 0.14 to 0.26 kgf m).

Note 2: Measure the pre-load by taking another rolling torque reading and subtracting the torque figure measured at step 6.3. The difference is the bearing pre-load. 15

Measure the crownwheel backlash which should be 0.13 to 0.2 mm (0.005 to 0.008 in). Adjust castellated nuts 5 and 6 by equal amounts when altering backlash. When backlash and pre-load are both correct, fit tension pins 3 and 4.

16

Verify crownwheel and pinion are set correctly: Use engineers marker on three of the pinion teeth and check markings on the crownwheel are as indicated on page F/24-6. Adjust if necessary.

17

Apply JCB Multi-Gasket to the drive head carrier mating face then fit to the axle casing (the carrier assembly locates on two dowels). Make sure the assembly is fitted in the same match marked position (see step 3, dismantling, page F/24-2).

18

Apply JCB Lock & Seal to bolts 1 and torque tighten to 166 Nm (122 lbf ft; 17 kgf m). Use heavy duty socket 892/00817.

Align the locating marks on the coupling yoke and splined shaft. Install the drive coupling yoke 23 and secure it with a new combined stake nut and washer 22: 6.1 Hold the yoke 23 with Service Tool 892/00812.

Note: Do not excessively hammer the yoke during assembly or damage to the shaft bearings could occur. If necessary, press fit the parts. Fully support the shaft during assembly. 6.2 Tighten the stake nut until end float is almost zero then check seal drag torque is between 0.40 to 0.75 Nm (3.5 to 6.6 lbf in). 6.3 Continue to tighten the stake nut to collapse spacer 30 and give a rolling torque of 1.7 to 2.8 Nm (1.3 to 2.1 lbf ft) excluding seal drag, crownwheel not fitted. IF THE STAKE NUT IS OVER-TIGHTENED, THE COLLAPSIBLE SPACER MUST BE RENEWED. Make sure that yoke 23 is rotated in both directions to fully seat bearings before measuring rolling torque.

Note 3: Verbus Ripp bolts must NOT be re-used. 19

Assemble both hub and driveshafts, refit the propshaft to the gearbox.

20

Fill the axle with recommended oil.

6.4 When the torque is correct, stake the nut to the pinion shaft using a square ended staking tool. 7

Fit crownwheel 20 to case half 13, torque tighten 'verbus ripp' bolts 19 to 166 Nm (122 lbf ft; 16.9 kgf m).

8

Assemble planet gears 16 and thrust washers 17 (4 off each) onto trunnion pins B. Fit the planet gear assembly and differential side gears 14, thrust washers 15 (2 off each) into case half 13.

9803/3270

Issue 1 SXXXXXX

SXXXXXX

SXXXXXX

Section F 24 - 6

Transmission Front Axle - SD70

Section F 24 - 6

Drivehead - Assembly (4WS Machines) Crownwheel and Pinion Adjustment 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.

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.

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.

9803/3270

Issue 1

Section F 25 - 1


Section F 25 - 1

Drive Head - Dismantling

ITL00670

9803/3270

Issue 1

Section F 25 - 2

Transmission

Section F

Front Axle - SD55

25 - 2

Drive Head - Dismantling (cont’d)

Drive Head - Assembly

1

Drain the oil from the drive head. Remove the propshaft.

Pinion Depth Setting Procedure (see Note)

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.

Place new pinion head 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.

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.

From the face of the pinion, obtain the etched deviation figure (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.

9

Remove the thrust washers 13 from both case halves.

10

Pull off the bearing 6 from case half 8A.

Obtain the deviation figure (e.g. - 1) stamped on the differential housing bolt flange. If negative, add to bearing depth; if positive, subtract from bearing depth.

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 collapsible 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.

9803/3270

ITL00560

Subtract the total of the above figures form the standard valve 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 Cap A Bearing depth Pinion deviation (+ 2) Housing deviation (- 1) Total

30.01 +0.20 30.21 +0.02 +0.01 30.24

Standard value Less Total above Shim Thickness

31.19 30.24 0.95

Note: See page F/25-5 for general guidance on crownwheel and pinion adjustment.

Issue 2

Section F 25 - 3


Section F 25 - 3

Drive Head - Assembly (cont’d)

ITL00670

9803/3270

Issue 1

Section F 25 - 4


Section F 25 - 4

Drive Head - Assembly (cont’d) Note 1 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.

10

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 4.

11

Measure the backlash between crownwheel 15 and pinion 20, which should be 0.13 - 0.20 mm (0.005 0.008 in). Adjust castellated nuts 4 by equal amounts when altering backlash. When backlash and preload are both correct, fit roll pins 3.

12

Check tooth marking as per page F/25-5 If incorrect, adjust.

13

Apply 4102/1212 Sealant 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).

14

Reassemble both driveshafts and hub assemblies (refer to page F/23-1).

Make sure all bearings are lightly oiled before fitting and setting. Make sure bearings are rotated whilst being set. 1

Select shim 23 required for pinion depth setting and fit behind new bearing cup 22. (See Pinion Depth Setting Procedure, page F/25-5).

2

Fit new pinion head bearing cone 22 onto pinion 20.

3

Fit a new collapsible spacer 24 onto pinion 20. Lightly oil pinion head bearing 22. Lightly oil pinion tail bearing 21 and fit the bearing. Using a suitable drift tap the tail bearing fully into position in the carrier. Locate the pinion in carrier 2. (Before inserting, ensure that the pinion matches crownwheel 15.) Insert a new oil seal 19 into housing. Pack grease between the seal lips. Align the locating marks on the yoke and splined shaft. Fit drive yoke 18 using a new stake nut 16.

Re-fill the hubs and differential with the correct grade of oil. Refit the propshaft (see page F/3-1).

Note: Do not excessively hammer the yoke during assembly or damage to the shaft bearings could occur. If necessary, press fit the parts. Fully support the shaft during assembly. 4

Tighten stake nut 16 until end float is almost zero, then check the seal drag torque is between 0.40 - 0.75 Nm (3.54 -6.64 lbf in). Continue to tighten the stake nut to collapse the spacer and give a rolling torque of 1.7 to 2.8 Nm (1.3 to 2.11 lbf ft) excluding seal drag. Record the rolling torque figure obtained. Rotate yoke 18 in each direction to bed in the bearings before measuring. Stake the nut when the pre-load is correct.

Note 2: If the specific rolling torque is exceeded, the collapsible spacer will be distorted. Renew the spacer and start again. 5

Assemble the trunnion pin 11, bevel gears 9 and 10 and their thrust washers 12 and 13 into differential half case 8A (see Note 1 above).

6

Position differential half case 8B onto half case 8A, aligning the match-mark letters (see Note 1 above). Apply JCB Lock and Seal 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.

7

Fit crownwheel 15 using new Verbus Ripp bolts 14 tightened to 94 Nm (69 lbf ft, 9.59 kgf m).

8

Locate crownwheel assembly (without bearings) into housing.

9

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.

9803/3270

Issue 3

Section F 25 - 5

Transmission

Section F

Front Axle - SD55

25 - 5

Drive Head - Assembly (cont’d) Crownwheel and Pinion Adjustment 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.

ITL00600

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.

ITL00610

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.

ITL00620

9803/3270

Issue 1

Section F 26 - 1


Section F 26 - 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/21-1 and F/21-2. 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/21-2), of the axle on 2 wheel drive machines will be the centre of the axle, NOT offset as described on page F/21-2.

9803/3270

Issue 1

Section F 27 - 1

Transmission

Section F 27 - 1

Front Axle

Dismantling and Assembly (2 Wheel Drive Machines) When Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling.

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

A suitable press will be required to remove and replace stub axle 22.

Item 3 9

Nm 40† 30

kgf m 4.0† 3.0

lbf ft 30† 21

When Assembling † Back off one flat before fitting split pin. 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.

S258280

9803/3270

Issue 1

9803/3270

Axle Arm Bolts JCB Multi-Gasket Grade 8.8 - 244 Nm; 24.9 kgf m; 178 lbf ft Grade 12.9 - 400 Nm; 40.8 kgf m; 295 lbf ft A363190

Axle Mounting Bolts 607 Nm; 62 kgf m; 448 lbf ft

Differential Case Bolts (8.8) JCB Threadlocker & Sealer 56 Nm; 6 kgf m; 42 lbf ft

Transmission

Propshaft Retaining Bolts (12.9) 79 Nm; 8 kgf m; 58 lbf ft

Stake Nut See Renewing the Pinion Oil Seal

Crownwheel Retaining Bolts (12.9) 166 Nm; 16.9 kgf m; 122 lbf ft

Trunnion Bolts JCB Threadlocker & Sealer 98 Nm; 10 kgf m; 72 lbf ft

Drain & Fill Plugs 79 Nm; 8 kgf m; 60 lbf ft

40 - 1

Planet Carrier Bolts (8.8)JCB Threadlocker & Sealer 56 Nm; 6 kgf m; 42 lbf ft

Wheel Nuts 680 Nm; 69 kgf m; 500 lbf ft

Typical axle shown, torque figures apply to AWS and 2WS machines - differences are indicated in text. When appropriate, the grade of the bolt is indicated either in the text or in parenthesis, e.g. ‘(12.9)’. Refer also to relevant dismantling and assembly procedures.

Rear Axle Torque Figures

Section F Section F

Rear Axle 40 - 1

Issue 2

Section F

Transmission

Section F 41 - 1

Rear Axle

41 - 1


D

C

D

-238.14

B H

H

E F J A

K G 9803/3270

A258190

Issue 1

Section F

Transmission

Section F 41 - 2

Rear Axle

41 - 2

Removal and Replacement (cont’d) Replacement

! 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.

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

GEN 1-1

Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

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

Using tool 892/00822 remove bolts A to disconnect the drive shaft from the axle.

2

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.

3

Remove the cover C from the proximity switch and then remove the bracket and switch assembly.

4

Label and then disconnect hydraulic pipes D from the steer rams, blank off all exposed connections.

5

Loosen the road wheel retaining nuts E.

6

Make sure that the front wheels are blocked, use the stabiliser legs to raise the rear end of the machine.

7

Prop the machine on each side as shown at F.

8

Remove the rear road wheels.

9

Position a jack underneath the balance point (centre) of the axle and support the axle weight.

! WARNING Bleed the brake system before driving the machine. BRAK 1-6

Bleed the brake system as described on page G/11-1. Apply JCB Lock & Seal to the threads of bolts A. If the setting of the steering proximity switch has been disturbed, then complete the rear axle proximity switch setting procedure, as described on page H/35-1. Torque Settings Item A E G

Nm 79 680 607

kgf m 8 69 62

lbf ft 58 500 448

Note: Attach a 'cradle' to the jack that will partially embrace the axle. 10

Remove nuts G, bolts J and washers K.

11

Lower the jack and remove the axle.

9803/3270

Issue 1

Section F 42 - 1

Transmission Rear Axle - PD70/SD70

Section F 42 - 1

Renewing the Pinion Oil Seal The procedure for renewing the rear axle pinion oil seal is the same as for the front axle pinion oil seal. Please refer to page F/22-1 for a full description of the procedure.

9803/3270

Issue 1

Section F


43 - 1

* Brakes

Section F 43 - 1

(without controlled back off)

Dismantling

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.


Note: The driveshaft is not shown on the illustration but this job can be done without removing the swivel hub or the driveshaft. 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.

Note: The plate carrier 3 has an internal chamfer at the end which faces away from the drivehead.

Y

C 3A

9803/3270

Issue 4*

Section F

Transmission

Section F 43 - 2

Rear Axle - PD70/SD70

43 - 2

6

Wear limit of friction plates is to the depth of the circumferential grooves X on early machines or cross hatching Y on later machines. 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.

8

Carefully withdraw the brake piston 6 from its housing, if removal is necessary. A hydraulic hand pump can be used to force the piston out of the housing.

Note: Steer axles are fitted with a different type brake carrier 3A.

Remove and discard seals 7 and 8. Inspect the housing bore for damage and scoring. Nicks or cuts in the seals may be responsible for loss of brake fluid.

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.

9

Assembly 1

Fit new seals 7 and 8. Make sure they seat squarely in their grooves.

2

Carefully press the piston 6 all the way into its housing.

3

* On assembly of the brake packs, the oil flow holes C must be aligned with each other when being fitted to the brake plate carrier.

4

Locate the three reaction pins 5 into their grooves, securing them with grease. Push the pins fully into their location holes in the housing.

5

Install one counterplate 2 into the housing, then the brake pack, then the other counterplate. Ensure that the chamfered end of the brake carrier 3 faces away from the drive head. Return re-used counterplates to their original positions. Push the brake pack fully home.

6

Apply JCB Multi-Gasket 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.

7

Fit bolts 1 and torque tighten.

* From serial number 337001, the dimensions A and B of the brake pistons and piston housings have been changed which affects service interchangeability. Old brake pistons and old housing must not be mixed with new brake pistons or new housings, refer to below on how to identify pistons and housings. Left and right hand sides of the axle can be mixed but, must be checked in the event of a replacement brake piston or housing being fitted. The brake seals are unchanged and will fit both old and new types of pistons and housings.

Assemble the friction plates and counterplates 2 onto the brake carrier 3, see note. If the original brake pack is being re-used, return the plates to their original positions (see 'Dismantling', Step 4.) Soak new friction plates in JCB Special Gear Oil before assembly. Fit circlip 4.

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).

To identify old and new brake housings A and brake pistons B measure the components as shown on illustration: Brake housing A Old up to 42.0 mm (1.65 in) New over 44.0 mm (1.73 in)

450/10409 458/20235

Brake piston

453/00104 458/20236

B Old 55.6 mm (2.18 in) New 57.5 mm (2.26 in)

A B

348090

9803/3270

Issue 4*

Section F

Transmission

Section F 43 - 3


43 - 3

8

7 9

16

15

5 11

10 17

13 14 12

3 2 B A

2 3A

4

1

6

378120

9803/3270

Issue 1

Section F

Transmission

Section F


43 - 4

43 - 4

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 prevent damage to the bearings and preserve the crownwheel and pinion backlash setting.

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.

! WARNING

11

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.

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.

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

Before removing the brake housing and piston assembly support the differential with a drive shaft or other suitable support, as shown at 6.

9803/3270

Issue 1

Transmission

Section F

Section F 43 - 5


43 - 5

8

7 9

16

15

5 11

10 17

13 14 12

3 2 B A

2 3A

4

1

6

378120

9803/3270

Issue 1

Section F 43 - 6


Section F 43 - 6

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.

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).

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.

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 1

Rear Axle - SD70

44 - 1

S268210

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 2

Rear Axle - SD70

44 - 2

* Doweled

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 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 spacer 9.

9

Remove the bolts 10.

10

Mark the relationship between the annulus carrier, annulus ring and hub swivel, remove the annulus carrier 11 with annulus ring 12.

11

Remove circlip 13 to separate the annulus ring 12 from the annulus carrier 11.

12

Pull off the bearing carrier 14 together with the outer bearing 15.

13

Pull off the inner bearing 16.

14

Remove and discard combination oil seal 17.

15

Mark the position of top and bottom trunnions 18 and remove. Withdraw the hub carrier 23.

17

Remove seal 21 and needle roller bearing 22 from swivel hub 23.

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 24.

19

Remove drive shaft inner seal 25.

20

Remove circlip 26, then remove bearing 27.

Note: Trunnions may be removed easily by pumping grease through the grease nipple. 16

Using a puller, remove the trunnion seal 19 and bearing 20.

9803/3270

Issue 2*

Section F

Transmission

Section F

44 - 3

Rear Axle - SD70

44 - 3

A

S268210

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 4

Rear Axle - SD70

44 - 4

* Doweled 1

Hub-Assembly

10

Install the drive shaft inner bearing 27 and secure with circlip 26. Fit new oil seal 25. Pack grease between lips of seal.

2

Fit drive shaft 24 inner end into splines of differential gears.

3

Fit needle roller bearing 22 and seal 21 into hub swivel 23.

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.

Note: Do not force fit bearing 22 and make sure the manufacturer’s mark is facing out. 4

Locate hub swivel, aligning relationship lines, assemble top and bottom trunnions 18 together with trunnion seal 19 and bearing 20. Torque tighten trunnion retaining bolts A to 98 Nm (72 lbf ft).

5

Lightly oil the inner wheel bearing race. Assemble the bearing cup 16 and bearing race into the bearing carrier 14.

6

Fit a new combination seal 17 into the bearing carrier 14 so that the chamfer faces the hub swivel. Do not disassemble seal or use excessive force when fitting.

7

11

Torque tighten bolts 10 evenly to 320 Nm (236 lb ft).

12

Measure the rolling force as follows:

Lightly oil the outer wheel bearing race. Assemble the bearing cup 15 and bearing race into the bearing carrier 14. Fit bearing carrier 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. 8

9

Align relationship marks made on dismantling. Assemble the annulus ring 12 to the annulus carrier 11. Secure with circlip 13. Fit annulus assembly in the same angular position as removal, using new bolts 10. Do not fully tighten bolts but allow the bearing carrier to rock slightly.


9803/3270

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 10) 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 necessary; and/or new fitted components. Remove planet gear carrier 2.

13

Press the drive shaft thrust pad 6 (chamfered side lowermost) into the recess in the planet carrier 2.

14

Fit new planet gears 4 in place of any that were removed.

15

Slide the sun gear 8 (chamfer to be inboard) onto the drive shaft 24 and secure with circlip 7. Fit a new 'O' ring 3 in place of the one discarded at Step 3 of 'Dismantling'.

16

Fit the planet carrier 2 onto the bearing carrier 14 ensuring that the two tapped holes are in line with those on the bearing carrier. Fit and tighten screws 1 after applying JCB Lock and Seal to the threads. Torque screws to 56 Nm (41 lb ft).

17

Fill hubs with correct grade oil.

Issue 3*

Section F

Transmission

Section F

44 - 5

Rear Axle - PD70

44 - 5

Hub-Dismantling & Assembly The procedures for dismantling and assembling the hub on a PD70 axle are virtually the same as for a SD70 axle described on the previous pages (F/44-1 to F/44-4). However, note that the wheel bearing carrier (item 5) is mounted directly on to the axle arm (item 1). Disregard references to the hub carrier (shown as item 23 on page F/44-1). For reference, a full sectional view of the PD70 axle arm and wheel hub assembly is shown below.

1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 28 29 33

Axle Arm Taper Roller Bearing Seal Wheel Bearing Carrier Wheel Stud Annulus Carrier Ring Dowel Verbus Ripp Bolt Annulus Ring Circlip Internal Planet Gear Planetary Hub Carrier Cylindrical Roller Bearing Circlip L Shaped Circlip External Thrust Pad Drive Shaft Sun Gear Circlip External Set Screw 'O' Ring Seal Oil Level Filler Plug Brake Friction Plate Brake Counter Plate Reaction Pin Circlip Internal Plate Carrier

A266870

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 6

Rear Axle - SD70

44 - 6

14

13

5

4

11

12

2 7 10 8 6

20 19 3

22 23 24 25 21 18

26

15

5 16

2 17

1

A313631

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 7

Rear Axle - SD70

44 - 7

Splined 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.

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.

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.

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.

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.

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 8

Rear Axle - SD70

44 - 8

14

13

5

4

11

12

2 7 10 8 6

20 19 3

22 23 24 25 21 18

26

15

5 16

2 17

1

A313631

9803/3270

Issue 1

Section F

Transmission

Section F

44 - 9

Rear Axle - SD70

44 - 9

Splined Hub-Assembly

9

Measure seal drag rolling force as follows:

1

Fit drive shaft 26 inner end into splines of differential gears.

a

Refit the planet gear carrier 2 - DO NOT FIT THE SUN GEAR 8.

2

Fit needle roller bearing 25 and seal 24 into hub carrier 21. Pack grease between the lips of seal 24.

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.

Note: Do not force fit bearing 25 and make sure the 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 lubricate before fitting. Use service tool (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.

10

Torque tighten bolts 10 evenly to 166 Nm (122 lb ft, 17 kgf).

11

Measure the rolling force as follows:

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

8

Align relationship marks made on dismantling. Assemble the annulus ring 13 to the annulus carrier 12. Secure with circlip 14. 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.


9803/3270

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 necessary; and/or new fitted components. 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 planet gears 4 in place of any that were 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.

Issue 1

Section F 45 - 1

Transmission

Section F

Rear Axle - SD70/PD70

45 - 1

Drive Head-Dismantling As the drivehead cannot be dismantled whilst fitted on the machine, we recommend that the complete axle is removed. See pages F/43-1 to F/43-4 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

1 2

Position the drive head as shown, with the crownwheel at the top. (For coupling removal, see page F/22-1) Remove capscrews.

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 pin regardless (to allow sideload adjustment on assembly).

S256050

3

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

6 7

Using a soft faced hammer, hit the pinion end shaft until the pinion is free from its front bearing, then withdraw the pinion. Withdraw the pinion seal and outer bearing cone. 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.

7 7 6

S256080

9803/3270

7

5

6 Issue 1

Section F 45 - 2

Transmission

Section F


45 - 2

Drive Head-Dismantling (cont'd) 8

Remove and discard the pinion collapsible spacer.

9

Pull off the bearing cone.

9

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

9803/3270

Issue 1

Section F

Transmission

Section F


45 - 3

45 - 3

Drive Head-Assembly Pinion Depth Determine the pinion depth setting as follows: Note: See page F/25-5 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.

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.

S184400

D B

S256110

Example (Dimensions in mm) Dimension A Add tool depth Total

Add dimension B if positive. (Subtract if negative.) Total

0.25 + 30.01 30.26

+ 0.01

C

30.27 S256120

Add dimension C if negative. (Subtract if positive.) Total

Standard Value Less calculated total from above SHIM THICKNESS

+ 0.01 30.28

31.19 - 30.28 0.91

Note: In rare instances, it is possible that the setting data stamp may be omitted from the drivehead casing. In these circumstances the following setting procedure should be used:

9803/3270

Issue 2*

Section F 45 - 4

Transmission

Section F


45 - 4

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 not use unmatched halves. If required, fit 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.

9

8

8 7 S256100

7

Fit the pinion inner bearing cone and a new collapsible spacer.

9

9

S256090

10

11

12

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.

0

Insert the pinion into its bore. (Before inserting, ensure that the pinion matches the crownwheel. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same.

0 @

Fit the pinion outer bearing cone and the seal. Pack between the lips of the seal with grease before fitting. S256080

13

Install the drive coupling yoke and secure with a new stake nut and washer. Tighten the stake nut (holding the yoke with Service Tool 892/00812) to achieve the correct rolling torque; see Step 14. If the nut is overtightened, the collapsible spacer must be renewed.

14

Measure the rolling torque, which should be 1.7-2.8 Nm(1.3-2.1 lbf ft; 0.17-0.28 kgf m). When the torque is correct, stake the nut to the pinion shaft using a squareended staking tool.

0

!

@

S256130

9803/3270

Issue 1

Section F 45 - 5

Transmission

Section F


45 - 5

Drive Head-Assembly (cont'd) 15

If both brake piston housings were removed, fit the one at the opposite end to the crownwheel, using the procedure in Step 16. Then install the crownwheel /differential assembly into the drive head.

S256070

16

17

Apply JCB Multi-Gasket to the drive head mating face, then fit the brake piston housing. Ensure that the match - marks made during dismantling are aligned. Fit capscrews. Torque - tighten to 56 Nm (42 lbf ft, 5.7 kgf m). (Applies to both piston housings.)

*

& ^

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 14. The difference is the bearing preload.)

S256140

18

Measure the crownwheel backlash, which should be 0.13-0.2 mm (0.005-0.008 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 17.

S256150

9803/3270

Issue 1

Section F

Transmission

Section F

46 - 1

46 - 1

Limited Slip Differential

5 6

7

8 9

1

10 13

14

12 10 9

8 7

6

3

11

4 2

S212800

S171530

S212790

9803/3270

Issue 2

Section F

Transmission

46 - 2

Section F 46 - 2

Limited Slip Differential Dismantling and Assembly

Friction Plate Wear Limits

The numerical sequence shown on the illustration is intended as a guide to dismantling

Measure and note the thickness of the friction plate, the result must not be less than 1.25 mm (0.049 in).

When Dismantling

Check the condition of the friction material, which should be even over both surfaces.

Mark the two differential halves before dismantling, for subsequent assembly.

If in doubt, discard the set (friction and counter plates).

Note the relative positions of the friction and counter plates before dismantling, they must be fitted in the same 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.).

Note: Shimming must be carried out whenever the 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, refer to page F/20-1 for torque figures.

9803/3270

Issue 1

Transmission

Section F 60 - 1

Section F

Syncro Shuttle Transmission

9803/3270

L

General Description and Operation

B

C

A

H

F

F

G

E

K

D

A355970

60 - 1

Issue 2

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.

In neutral the flow of the pressurised oil is blocked at the solenoid valve. When either forward or reverse is selected, the solenoid valve E diverts pressurised oil via the reverser shaft to the appropriate clutch in the reverser unit A. A restrictor orifice in the feed to the solenoid valve modulates the pressure to the clutch to smooth engagement. Pressure from the other clutch is vented back to the sump via the solenoid valve spool.

Transmission

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. A full description of 2/4 wheel drive clutch operation is given on page F/60-6.

Oil from the torque converter flows out of the transmission to the external oil cooler, returning at the rear of the transmission unit to pass through the centre of the reverser shaft for clutch lubrication.


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. The synchromesh units are of the 'Blocking Pin' type, a full description of which is given on the next page.

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. Oil enters the converter between the converter hub and the stator support, and leaves between the stator and the input shaft. Pressure in the converter is controlled by a relief valve C which dumps oil from the converter line back to the sump.

Section F

This Illustration shows a typical JCB Syncro Shuttle which consists of a torque converter, hydraulic reverser unit, and integral manual 4-speed gearbox.

60 - 2

9803/3270

General Description and Operation

Section F

60 - 2

Issue 2

Section F

Transmission

Section F 60 - 3


60 - 3

Synchromesh

A

B

C

E

D F

9803/3270

G

Issue 1

Section F 60 - 4

Transmission Syncro Shuttle Transmission

Section F 60 - 4

Synchromesh (cont’d) Description

Operation

The gearbox is fitted with 'Blocking Pin' synchromesh, comprising the following parts.

Diagram F shows the gearbox with first gear engaged. Synchro ring B is in contact with synchro cup E and the synchro hub dog teeth are linking first gear to the shaft gear. In this position the split energiser pins D are 'collapsed'.

SYNCHRO 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 synchro hub centre are two sets of holes for the blocker pins (C) and the split energiser pins (D), spaced alternately. SYNCHRO RINGS (B) are rigidly joined by the blocker pins, with the split energiser pins held, in counterbores, between the two synchro rings. BLOCKER PINS (C) have a narrow neck in the centre, against which the synchro hub transmits radial drive during gear changes. The edges of the blocker pin neck and their mating synchro hub holes are designed so that, as the radial loads are reduced, the synchro hub can slide over the shoulder of the blocker pin. SPLIT ENERGISER PINS (D) take the initial axial load of the synchro 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 synchro hub to move axially. SYNCHRO CUPS (E) take the frictional drive from the synchro ring on their inner faces. The synchro cups are splined to drive their respective gears whilst synchronisation is taking place.

When selecting second gear the synchro hub A slides along the split energiser pins until the pin recess and the synchro hub flange are in line. At this point the split energiser pins open and the synchro rings are moved by the synchro hub pushing on the split energiser pin shoulder. Initial contact between the synchro ring and the synchro cup starts to synchronise the speed of the shaft and second gear. The rotational force of the synchro ring is taken by the blocker pin against the edge of the synchro hub hole, as at G. As the axial load on the synchro hub increases, the split energiser pin 'collapses' and the conical faces of the blocking pin and synchro hub hole come into contact, as at H. Further increases in the axial loads increase the frictional grip of the synchro ring and the synchro cup, causing the shaft and gear speeds to synchronise. As the speeds are synchronised the radial load on the blocker pin and the synchro hub is reduced. This allows the synchro hub to slide freely along the blocker pin and engage its dog teeth with second gear, see diagram J.

S05171

9803/3270

Issue 1

In neutral, the flow of pressurised oil to the clutches is blocked by the solenoid valve. When either forward or reverse is selected, the solenoid valve diverts pressurised oil via the reverser shaft to the appropriate clutch in the reverser unit. Pressure from the other clutch is vented to the sump via the solenoid valve spool.

Section F

60 - 5

9803/3270

Clutch Operation

Transmission


A258660

Section F

60 - 5

Issue 1

This clutch is of the 'Pressure-ON (4WD)/SpringOFF (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.

Section F

60 - 6

9803/3270

4 Wheel Drive Operation

When the switch is in the 4 wheel drive position solenoid valve A is energised. The energised valve causes spool F to move to the right and forms a connection between ports 3 and 2.

2 Wheel Drive Operation When the switch is in the 2 wheel drive position, solenoid valve A is de-energised. With the solenoid valve de-energised, the oil supply to the piston C is blocked (shown at port 3). The solenoid valve in the de-energised position also vents oil from the back of piston C to the sump via ports 1 and 2. Because there is no pressure behind piston C, the clutch plates freely rotate on the output shaft, thus disengaging drive to the front axle.

Transmission


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.

S264690

Section F

60 - 6

Issue 1

Section F 61 - 1

Transmission

Section F


61 - 1

Fault Finding 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 B C D E F G

If the transmission is noisy, start at check 1. If the transmission is overheating, start at check 4. If the transmission will not pull, start at check 12. If there is no drive in one or both directions, start at check 17. If the transmission is jumping out of gear, start at check 29. If the transmission is sticking in gear, start at check 39. If ratios are 'crash changing', start at check 41.

CHECK

ACTION

1

Is there noise when selecting direction?

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?

YES: Continue running to expel air. NO: Check 4

4

Is the fluid level correct?

YES: Check 5 NO: Check level only when machine is cold and top-up as required.

5

Are the oil passages restricted?

YES: Clear the restriction. NO: Check 6

6

Is the suction strainer restricted?

YES: Remove and clean strainer. NO: Check 7

7

Is pump pressure as specified?

YES: Check 9 NO: Check clutch pressure maintenance valve is free to operate.

8

When flow testing pump, is output low?

YES: Renew pump. NO: Check converter sprag clutch for wear or slip.

9

Does the noise continue when direction selector is in forward or reverse?


10

Is transmission misaligned?

YES: Renew mountings and check position. NO: Check 'converter out' pressure and flow.

11

Are the pump bushes worn?

YES: Renew NO: Check converter for wear or cooler for restriction to flow.

12

Is the transmission not pulling in one direction only?


13

Is the transmission not pulling in both Forward and Reverse?

YES: Stall test machine, Check 14. NO: Check 16

9803/3270

Issue 1

Section F 61 - 2

Transmission

Section F


61 - 2

Fault Finding (cont'd) CHECK

ACTION

14

Is 'converter in' pressure as specified?

YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass valve pressure setting.

15

Is pump being driven by converter?

YES: Check pump pressure. NO: Renew damaged parts.

16

Are clutch sealing rings damaged?

YES: Tap pressure gauge into clutch feed lines to monitor pressure. NO: Check clutch plates for damage.

17

Is there drive in one direction only?


18

Is the start switch in the run position and supplying current to the neutral start relay?

YES: Check 19 NO: Rectify.

19

Is the fault only when the transmission is hot?

YES: Dismantle solenoid and check components. NO: Check microswitches, relay and wiring loom.

20

Is the noise a growl, hum or grinding?

YES: Check gears for damage or wear. NO: Check 21

21

Is the noise a hiss, thump or bumping?

YES: Check bearings for damage or wear. NO: Check 22

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: Adjust by checking shaft end float. NO: Check 26

26

Is the mainshaft pilot bearing worn?

YES: Renew. NO: Check gear teeth for scuffing.

27

Is the mainshaft rear bearing worn?

YES: Renew. NO: Check 28

28

Are the sliding gear teeth worn or damaged?

YES: Renew gears. NO: Check 29

29

Are the selector forks loose?

YES: Tighten screws. NO: Check 30

30

Are the selector fork pads or grooves in gears worn?

YES: Renew worn parts. NO: Check 31

31

Are the dog gear teeth worn?


32

Are the selector rod detent springs broken?


9803/3270

Issue 1

Section F 61 - 3

Transmission

Section F


61 - 3

Fault Finding (cont'd) CHECK

ACTION

33

Are the selector rods worn or damaged?


34

Are the selector fork pads out of position?

YES: Reposition or renew (check interlock). NO: Check 35

35

Is there excessive end float in gears or shafts?

YES: Adjust. NO: Check thrust washers and mating faces.

36

Is the synchroniser bronze worn?

YES: Renew synchro pack. NO: Check 37

37

Are steel chips embedded in the bronze?

YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 38

38

Are the synchroniser components damaged?

YES: Renew. NO: Check free running gears for seizure or damage.

39

Are the sliding gears tight on the splines?

YES: Free or renew. NO: Check 40

40

Are chips wedged between splines of shaft or gear?

YES: Remove chips. NO: Ensure that clutch is disengaged when dump pedal is pressed.

41

Are steel chips embedded in the bronze?

YES: Continue using, chips will either embed below bronze or be rejected. NO: Check 42

42

Are the synchroniser spring pins damaged?

YES: Renew synchro. NO: Check 43

43

Is the synchroniser bronze worn?

YES: Renew synchro. NO: Check blocker pins.

9803/3270

Issue 1

Section F

Transmission

Section F


61 - 4

61 - 4

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 2 3 4 5 6

Check that the transmission oil level is correct. Check that the fuse for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact. Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position). Check that the mainline pressure is correct (see 'Low Mainline Pressure'). Check that the pump flow rate is correct.

If the fault is not rectified after eliminating the obvious, check the following:

Possible Cause

Remedy

7

7

Low mainline pressure

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

Rectify fault:

8.1 2/4WD solenoid spool sticking.

8.1 Strip, clean and re-assemble solenoid valve, renew valve if required.

8.2 2/4WD solenoid spool O-ring failed.

8.2 Renew O-ring.

8.3 Clutch shaft sealing rings leaking.

8.3 Renew clutch shaft sealing rings.

8.4 Excessive clutch shaft end float.

8.4 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001

in)

9

8.5 Wrong type clutch piston fitted.

8.5 Fit correct type clutch piston (ie, without bleed hole).

8.6 Clutch piston O-ring failed.

8.6 Replace clutch piston O-ring.

Defective 2/4WD clutch:

9

Rectify fault:

9.1 Worn friction/counter plates

9.1 Inspect friction/counter plates, renew as required.

9.2 Mechanical failure of 4WD unit

9.2 Strip and inspect 4WD unit. Check that the electrical and hydraulic circuits are functioning correctly.

9.3 Incorrect clutch pack end float. to

9.3 Measure clutch pack end float (should be 1.0 2.3 mm). Correct as required.

9803/3270

Issue 1

Section F 61 - 5

Transmission

Section F


61 - 5

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

Remedy

10

10

Incorrect type of solenoid valve fitted.

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. Note: NOT fitted on Powershift machines.

12

2/4WD solenoid permanently energised.

9803/3270

12

Check the 2/4WD relay and select switch, replace as necessary.

Issue 1

Section F

Transmission

Section F 62 - 1


62 - 1


C E

P

A258630 S264620

9803/3270

Issue 1

Section F

Transmission

Section F 62 - 2


62 - 2

Removal and Replacement (cont’d)

13

Using the trolley jack, lower the transmission and engine to gain access to the top flywheel housing to engine block retaining bolts J.

14

Disconnect the transmission oil cooler at the transmission unit, shown at B and N.

15

Disconnect the transmission solenoid valve flying lead connectors A and the pressure sender. Label the connectors for identification when refitting.

16

Remove the breather pipe from the pressure maintenance valve block to top of the dipstick tube as shown at M.

17

Put a support under the engine as shown at G to prevent it from dropping when the transmission is removed.

18

Remove the flywheel housing to engine bolts J.

19

Manoeuvre the transmission with the torque convertor clear of the engine housing.

20

Lower the trolley jack and pull the transmission and torque convertor clear of the machine.

Park the machine on firm level ground.

! 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

Rest the bucket on the ground and raise the stabiliser legs sufficiently to allow room for the transmission to be pulled clear. Block/support the machine.

2

Drain the transmission system, see page 3/12-1.

3

Remove the engine bonnet, see page 3/4-1.

4

Remove the engine fan retaining bolts P (4 off) and remove the fan, see note 1.

Note 1: At a later stage the transmission is tilted to give access to retaining bolts, if the fan is not removed at this stage it will foul. 5

Disconnect the gearshift lever from the top of the transmission as shown at D.

6

Remove rear axle drive shaft bolts E.

7

Remove 4WD shaft bolts F (use tool 892/00822) and 4WD solenoid flying lead connector L.

8

Disengage the parking brake clevis at the parking brake caliper and remove outer cable retaining circlip as shown at C.

9

Remove the transmission dipstick tube and filter.

10

Remove the access bung/plate at the bottom of the flywheel housing. Through the access hole, loosen and remove the torque convertor to engine flywheel retaining bolts Q.

11

Support the transmission with a trolley jack as shown at H, see note 2.

Replacement Replacement is a reversal of the removal procedure. Set the parking brake cable as described on page 3/7-1. If the parking brake caliper has been removed reset central to the parking brake disc, see G/22-4. Set the torque converter as described on page F/69-1. Fill the transmission with the specified amount of JCB Special Transmission Fluid (3/1-2 for capacity). Leave hose N off until the filling operation is complete. After filling refit hose N. Torque Settings Item E F J K P Q

Nm 118 79 98 237 25 44

kgf m 12 8 10 24 2.5 4.5

lbf ft 87 58 72 175 18 32

Note 2: Attach a 'cradle' to the trolley jack that will partially embrace the transmission, see Service Tools, Section 1. 12

Make sure that the weight of the transmission is supported by the trolley jack and remove the transmission mounting bolts K.

9803/3270

Issue 1

Sheet 1 of 3 Torque Figures and Assembly Notes

13

4

20

Torque Settings

1 12

4

11

Nm 102 35 85 56 8 - 10 5-8 10 20 - 24 28 75

lbf ft 75 25 63 41 5.9 - 7.4 4.0 - 5.9 7.4 14.8 - 17.7 20 55

kgf m 10.4 3.5 8.6 5.7 0.8 - 1.0 0.6 - 0.8 1.0 2.0 - 2.9 2.8 7.5

Assembly Notes Item

11

11

Bearings to be lightly oiled before setting and must be rotated whilst being set.

12

Pack cavity between seal lips with grease before assembly.

13

Select shims to give input shaft end play of 0.03 mm to 0.08 mm.

14

Select shims to give mainshaft end play of 0.03 mm to 0.08 mm.

15

Select shims to give layshaft end play of 0.03 mm to 0.08 mm.

16

Select shims to give 4WD shaft end play of 0.03 mm maximum.

14 11 12 11

4

19

Notes

Transmission

17


9

Item 1 2 3 4 5 6 7 8 9 10

Section F

Section Views and Torque

63 - 1

9803/3270

* SS640

4 18 15

20

16

11 9

A264540

63 - 1

Issue 2*

8 5

Cont’d...

Section F

11

Sheet 2 of 3 Assembly Notes (cont’d) Item

18

Tighten stake nut to a torque of 400 Nm and stake nut sleeve using square ended staking tool.

6

* 19

The transmission should be rebuilt with a solid spacer, which is the preferred option. However in the absence of the special tools required or of a solid spacer, a collapsible spacer may be fitted.

20

Apply grease to shaft before assembly.

4 4

9 2 2 3 8

Transmission

The procedure for tightening the stake nut varies depending on whether a solid spacer or collapsible spacer is fitted. See Assembly procedure for details.


* 17

7

2

Notes

Section F

SS640 Section Views and Torque Figures (cont’d)

63 - 2

9803/3270

*

4 9 4 4

Section F

63 - 2

Issue 2*

A264560

Issue 2*

A264550

63 - 3

Section F

1

Transmission

9


4

Section F

9803/3270

11 1 1

63 - 3

Sheet 3 of 3 SS640 Section Views and Torque Figures (cont’d) *

2 7 4

Section F 64 - 1

Transmission

Section F


64 - 1

Gearbox - Dismantling 1

Drain the oil from the casing by removing the suction strainer.

2

Remove and discard the oil filter.

2

1 221010

3

Unscrew bolts and withdraw pump.

4

Remove and discard pump sealing ring.

5

Separate pump components.

6

Remove and discard oil seal from pump housing.

3

5

6

9803/3270

4

221020

Issue 1

Section F 64 - 2

Transmission

Section F


64 - 2

Gearbox - Dismantling (cont'd) 7

Position transmission vertically, standing on the face of the flywheel housing. Remove gear lever turret.

8

Unscrew capscrews and remove solenoid selector valve. Note ‘O’ rings fitted around ports on mating face of solenoid valve body.

7

Note: See page F/66-1 for solenoid dismantle/assembly .

8

221050

9

Slacken worm drive clips and remove rubber boot. Remove spring retaining circlip X.

X

Note: BEWARE of spring pressure acting on nylon seat when circlip is removed.

A258650

10

Components of one piece gear lever turret.

A258640

9803/3270

Issue 1

Section F 64 - 3

Transmission

Section F


64 - 3


Unscrew four bolts and remove pressure maintenance valve.

12

Unscrew plug and withdraw pressure maintenance valve spool and spring.

12

11

221060

13

Remove torque converter pressure relief valve ball and spring.

14

Unscrew bolts and lift off output end casing.

14

13

221070

9803/3270

Issue 1

Section F 64 - 4

Transmission

Section F


64 - 4


Unscrew selector detent plugs.

16

Remove selector detent balls and springs.

17

Unscrew selector fork retaining screws and lift out selector rods.

18

18

17

Remove selector forks.

15

16 221080

19

Using a wire support as shown, remove interlock plunger situated between selector rod bores.

20

Lift off 3rd/4th syncro-hub. Note the positions for refitting with mating cups.

21

Lift out layshaft assembly .

20

21 19

S221090

9803/3270

Issue 1

Section F 64 - 5

Transmission

Section F


64 - 5


Remove idler gear upper thrust washer.

23

Tilt mainshaft L to one side and lift off idler gear.

24

Remove idler gear lower thrust washer.

25

Lift off idler gear spacer.

26

Tilt mainshaft L to one side and lift out reverser assembly taking care not to damage piston ring seals.

22 23 24 L

25

Note: See pages F/67-1 to F/67-4 for reverser unit dismantling and assembly procedures. 27

Remove mainshaft L.

28

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.

26

S221101

29

Whilst holding brake disc with tool 992/04800, unscrew output shaft nut. Support output shaft from beneath and lift off brake disc.

30

Prise out oil seal and discard.

31

Withdraw output shaft assembly and lift out outer bearing. Remove spacer N and retain for assembly.

29

30

Note: If spacer N is the collapsible type discard it. 32

Using a suitable puller, withdraw output shaft inner bearing.

* 33

If required, the new type parking brake bracket A can be removed at this stage, before removing mark the position of the bracket relative to the casing.

A

N 31 32 S221111 S221111

9803/3270

Issue 3*

Section F 64 - 6

Transmission

Section F


64 - 6


Pull off 3rd gear, syncro-hub and bearing from mainshaft using press 892/00179 with adaptor 992/06300.

34

Remove bearing from converter end of mainshaft using press 892/00179.

34 33 221140

35

Remove 4WD transfer gear and bearing from layshaft. On 2WD machines a spacer is fitted in place of the transfer gear.

36

Lift off 1st gear.

37

Remove 1st gear needle roller bearings.

38

Lift off 1st/2nd syncro-unit. Keep syncro cups and cones in the correct relationship, i.e. cup and cone as a pair.

39

Pull off 2nd gear, syncro-hub, syncro cup and needle roller bearing from layshaft.

39

38

37 36

35 221150

See pages F/68-1 and F/68-2 for the hydraulic 4WD unit dismantling and assembly procedures. Finally, after repair and renewal of parts, make sure casings and parts have been thoroughly cleaned using suitable solvents before starting the assembly procedures.

9803/3270

Issue 1

Section F

Transmission

Section F


64 - 7

64 - 7

Gearbox - Assembly 1

Smear bearing surface of shaft with JCB HP Grease and fit 2nd gear and syncro cup onto shaft.

2

Press 2nd gear syncro-hub and 1st gear needle roller bearing sleeve onto layshaft.

3

Fit 1st/2nd syncro unit correct way round to match cups.

4

Slide 1st gear needle roller bearings over sleeve. Smear bearings with oil.

7

5

Fit 1st gear over needle roller bearings.

6

Assemble 4WD transfer gear over splines. On 2WD machines slide spacer over splines.

7

Press bearing onto assembled layshaft and smear bearing with JCB HP Grease.

8

Smear bearing surface of mainshaft with JCB HP Grease and assemble 3rd gear and syncro-hub. Fit spacer washer S with bevel towards bearing. Press bearing onto shaft and smear with JCB HP Grease.

2 3

1

4 5

6 221150

S 221140

Note: If the new type parking brake mounting bracket A has been removed it must be fitted at this stage in the position as marked during dismantling, see page G/22-10 for torque figures. When building a transmission with a solid spacer a 15mm (0.50in) diameter hole will have to be drilled at B to enable the fitting of the tool for checking the end float. 9

a

82mm 75mm

S

Liberally coat output shaft inner bearing with JCB HP Grease before fitting inner bearing P.

Note: The gearbox may have been fitted with either a collapsible spacer or a solid spacer N. The preferred option is a solid spacer, fitting of which is described in the following procedure. However, in the absence of the special tools required or of a solid spacer, a collapsible spacer may be fitted as described under Collapsible Spacer - Assembly on page F/80-1.

A B

373140

b Fit the service solid spacer N (13.70 mm) over output shaft and assemble into casing. c

N

Lightly oil output shaft outer bearing and cup R and fit to output shaft, do not fit oil seal S at this stage. 221111

9803/3270

P R

S221111

Issue 4

Section F

Transmission

Section F


64 - 8

64 - 8

Assembling (cont'd) * 10 a Fit special tool sleeve A which temporarily replaces disc brake 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:

C B

D A

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 Fit special tool support pillar C so that the fork end engages in special tool nut B, tighten bolt D.

S265900

* 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

E

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 13.70 Subtract end float 0.41 Total 13.29 Subtract tolerance & preload Result 13.17

0.12

F

Use next smallest spacer ie. 13.15 If the ‘Result’ measurement is outside the spacer kit range use a collapsible spacer. See Collapsible Spacer Assembly on page F/80-1.

n s

d Remove sleeve A and fit correct size spacer. Take care to avoid damaging the outer bearing. e

f

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.

B A

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. S265900

9803/3270

Issue 2*

Section F

Transmission

Section F


64 - 9

64 - 9

Gearbox - Assembly (cont'd) * 12

a

Remove nut B and sleeve A. Fit new oil seal S, grease between seal lips before fitting. Assemble brake disc/flange. (The disc/flange may be a tight fit).

b 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 not exceed a maximum of 2.0 Nm (1.5 lbf ft) when fully torque tightened.

T

S

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. c

13

14

A273410

Finally stake nut T into slot.

Press idler gear spindle into casing. Ensure that oil drain hole V points toward bottom of casing.

13

14

V

Grease piston ring seal and pack solenoid end bearing with JCB HP Grease, then carefully lower reverser shaft into casing.

221180

15

Assemble two halves of the casing together and tighten bolts to 56 Nm (42 lbf ft).

15

Note: Assembling the case halves at this stage is a temporary arrangement to enable measurement of the reverser shaft end float. DO NOT apply JCB Lock & Seal to the bolts at this stage or bond mating faces. Note: To prevent damaging reverser unit piston ring seals, it is permissible to remove the seals prior to assembling case halves. However this is applicable only whilst measuring reverser shaft end float. REFIT THE SEALS BEFORE FINAL ASSEMBLY.

221190

9803/3270

Issue 2*

Section F 64 - 10

Transmission

Section F


64 - 10

Gearbox - Assembly (cont'd) 16

Measure end float of reverser shaft which should be 0.03 to 0.08 mm (0.001 to 0.003 in).

Note: Rotate shaft whilst measuring to seat bearings fully. Position pointer of dial test indicator on the chamfer of the shaft, not the end face. This will ensure a constant reading is given.

221200

17

Separate two halves of casing and add or subtract shims fitted beneath the bearing outer race (in the rear casing) in order to correct reverser shaft end float.

17

S221210

18

Smear mainshaft output end bearing with JCB HP Grease and place mainshaft L in position, followed by reverser assembly M.

19

Fit idler gear spacer.

20

Fit thrust washer.

21

Fit syncro cup to 3rd gear (mainshaft L). Lubricate idler gear needle roller bearing and assemble to spindle whilst tilting mainshaft L to one side.

22 21 20 19

22

L M

Fit thrust washer.

S222202

9803/3270

Issue 2

Section F 64 - 11

Transmission

Section F


64 - 11


Pack output end bearing of layshaft with JCB HP Grease, and carefully lower layshaft into position.

24

Fit 3rd/4th syncro-hub correct way round to mate with cups.

25

Using a suitable wire support locate interlock plunger into its bore. A smear of grease will hold the plunger in position.

24

23 25

221090

26

Fit selector forks into position.

27

Slide selector rods into position, taking care not to dislodge the interlock plunger. Apply JCB Lock and Seal to selector fork retaining screws H, and tighten to 35 Nm (26 lbf ft).

28

Fit selector detent balls and springs.

29

Apply JCB Lock and Seal to selector detent plugs, install and tighten. Check that each gear engages fully, and that the interlock plunger prevents simultaneous engagement of two ratios.

30

27 30

H

Apply JCB Multi-gasket to mating face of casing. Insert 'O' rings Z (located near the reverser unit). Smear grease onto reverser shaft piston ring seals, and apply JCB HP Grease to bearings prior to fitting output end casing.

28 29

Note: Make sure that the reverser unit piston rings are in good condition before fitting output end casing. Note: Do not apply an excessive amount of JCB Multigasket around the O-ring, too much can dislodge it.

Z S221080

221400

9803/3270

Issue 2

Section F 64 - 12

Transmission

Section F


64 - 12


Carefully lower output end casing into position. Apply JCB Lock and Seal to bolts and torque to 56 Nm (42 lbf ft).

31

221190

32

Remove layshaft bearing cap and substitute tool 990/00083 together with a new gasket. Tighten securing bolts to 56 Nm (42 lbf ft).

34

Note: Take care not to damage the gasket as it must be used for final assembly. 33

Measure layshaft end-float, which should be 0.03 to 0.08 mm (0.001 to 0.003 in).

Note: Rotate layshaft whilst measuring to seat bearings fully. 34

Add or subtract shims to correct end-float. Fit shims between outer race and spacer.

33

32 221230

9803/3270

Issue 2

Section F 64 - 13

Transmission

Section F


64 - 13


After checking that layshaft outer bearing is adequately lubricated with HP Grease, refit layshaft bearing cap with the gasket used in operation 32. Apply JCB Lock and Seal to bolts and tighten to 56 Nm (42 lbf ft).

35

221060

36

Unscrew bolts and remove the flywheel housing.

36

221260

37

Install tool 892/00295 over the mainshaft end bearing, as shown. Tighten securing bolts to 56 Nm (42 lbf ft).

38

Measure mainshaft end-float which should be 0.03 to 0.08 mm (0.001 to 0.003 in).

Note: Rotate mainshaft whilst measuring in order to seat bearings fully. 39

Add or subtract shims to correct the end-float. The shims must only be fitted between the bearing outer race and spacer.

37

38

39

221270

9803/3270

Issue 3

Section F 64 - 14

Transmission

Section F


64 - 14


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.

41

Install pump taking care to align mounting holes. Apply JCB Lock and Seal to bolts and, using new sealing washers, tighten to 28 Nm (21 lbf ft).

42

Check that the mainshaft end bearing is adequately lubricated with HP Grease. Prior to refitting the flywheel housing, apply JCB Multi-gasket to the flywheel housing face. Apply JCB Lock and Seal to the bolts and tighten to 56 Nm (42 lbf ft).

43

Fit torque converter pressure relief 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 Lock and Seal to plug, then tighten.

44

Assemble pressure maintenance valve spool and spring into adaptor block. Apply JCB Lock and Seal to plug, fit and tighten. Do not overtighten as damage to the aluminium housing could result.

45

Using a new gasket mount pressure maintenance valve onto casing. Apply JCB Lock and Seal to bolts and tighten to 7 Nm (5 lbf ft).

40 41

42

44

45

Note: To avoid contamination of sealant printed on gasket face keep in protective wrapper until needed.

43

221410

* 46

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 Lock and Seal to capscrews and tighten to 5Nm (3.7 lbf ft).

46

221050

9803/3270

Issue 2

Section F 64 - 15

Transmission

Section F


64 - 15


Assemble gear lever components, applying grease liberally to the working surfaces.

A258640 A258640

48

Refit components into gear lever housing, secure in position with retaining circlip X.

X

Note: If necessary use a bench press to compress the spring to allow fitting of the retaining circlip.

A258650 A258650

49

Using a new gasket fit gear lever turret to transmission. Apply JCB Lock and Seal to mounting bolts and tighten to 56 Nm (42 lbf ft). Check for gear selection.

49

221050

9803/3270

Issue 2

Section F

Transmission

Section F


64 - 16

64 - 16

Gearbox - 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. 50

Using a new gasket, install suction strainer. Apply JCB Lock and Seal to bolts and tighten to 10 Nm (7 lbf ft).

51

Fit a new filter:

52

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.

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.

51

50 221010

See pages F/68-1 and F/68-2 for hydraulic 4WD dismantling and assembly procedures.

9803/3270

Issue 2*

Section F 65 - 1


Section F 65 - 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

9803/3270

Issue 1

Section F

Transmission Synchro Shuttle Transmission

66 - 1

Section F 66 - 1

Solenoid 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 10 to 15

9803/3270

kgf m 1 to 1.5

lbf ft 8 to 10

Issue 1

Section F 67 - 1

Transmission

Section F


67 - 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

Loosen the clutch end bearing by tapping the assembly on a piece of wood as shown. Remove the bearing using pullers.

2

S232730

3

Remove the bearing, thrust washer and plastic type washer.

4

Withdraw the gear and splined hub assembly with the needle roller bearing.

3

4

S264660

5

Remove plastic type washer and thrust washer.

6

Remove the clutch friction/counter plates retaining circlip.

7

Remove pressure (end) plate.

5

6 7

S217540

9803/3270

Issue 1

Section F 67 - 2

Transmission

Section F


67 - 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 assembly.

Note: The disc spring is assembled within a liner (not shown) to protect the hub support spline.

8

9 10

S232741

11

Position clutch assembly in press to compress piston spring then remove circlip.

11

Note: If no press is available, spring compressor tool 892/00916 can be used.

12

12

Lift off spring retaining plate.

13

13

Remove spring. S145000

S264670

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. Make sure the piston liner is secure. The liner must be a tight fit on the piston.

16

Repeat steps 2 to 15 to dismantle the opposite clutch.

15

A264720

9803/3270

Issue 1

Section F 67 - 3

Transmission

Section F


67 - 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

A264720

2

Install the 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 S145000

2

S264670

5

Fit the disc spring assembly. Fit the assembly so that the outer diameter curves away from the clutch piston.

Note: The disc spring is assembled within a liner (not shown) to protect the hub support spline. 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

S232741

9

10

Fit the pressure (end) plate. 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.

9

S217580

9803/3270

Issue 1

Section F 67 - 4

Transmission

Section F


67 - 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.

Note: Later type shim has teeth on the outside diameter; the teeth prevent it from spinning during operation. If the shim removed from the clutch does not have teeth then discard it and use the new type shim.

S217590

12

Fit thrust washer and plastic type washer.

12

S217600

13

Fit gear and splined hub assembly.

Note: Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver). 14

Fit needle roller bearing.

15

Fit plastic type washer and thrust washer.

15 14

13

S232370

16

Smear the clutch end bearing with JCB HP Grease and press the bearing onto shaft.

17

Fit piston ring seals.

18

Repeat steps 1 to 16 for the opposite clutch, make sure that the opposite clutch end taper roller bearing is packed with grease.

17 16

S232720

9803/3270

Issue 1

Section F


68 - 1

Section F 68 - 1

Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON)

P S209050

9803/3270

Issue 3

Section F 68 - 2

Transmission

Section F


68 - 2

Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON) Dismantling

Assembly

Note: To aid working on this item, use the output yoke as a stand.

If only the clutch pack has been removed, begin at step 4.

1

Remove the 2/4WD unit from the casing - (loosen the output yoke retaining nut before removal if there is to be a complete strip down of the unit).

2

Remove the shaft components E - M.

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 bearings 6 and thrust washer 4. Remove thrust washer 7. (Note that thrust washers 4 and 7 are not interchangeable).

1

Grease the shaft, fit new 'O' rings 17 and 18 then locate piston 16 over the shaft and into the housing. It is reccommended that that aluminium type piston 16 as shown is used and not the plastic type.

2

Locate oil baffle 15A, spring 15 into the piston and position the retainer plate 14 over the spring.

3

Using a press and adapter Y, compress spring 15 and fit circlip 13.

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.

5

Install pressure plate 10, shim(s) 9 and circlip 8.

6

Measure the clutch pack end float using two screwdrivers as shown at B. End float should be between 1.0 mm and 2.2 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.

7

Remove pressure plate 10, the clutch pack friction plates 11 and counter plates 12.

7

Fit thrust washer 7, 4WD gear 5, needle roller bearings 6 and thrust washer 4.

Note: If only the clutch pack was to be removed, the job is now complete.

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.

9

Fit new seal 2.

10

If required, press a new bearing 1 into position, taking care not to exert any force on the housing (see Step 8).

8

Using a suitable press and an adapter similar to Y, compress spring 15 and remove circlip 13.

9

Remove spring retainer plate 14, spring 15 and oil baffle 15A.

10

Withdraw piston 16 then remove and discard 'O' rings 17 and 18.

*

See note after step 17. Note: The piston housing cannot be separated from the shaft, as on the other types of 2/4WD units.

11

Fit the 2/4WD unit to the transmission using a new gasket C. Apply JCB Threadlocker & Sealer to the mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft.

12

Fit the output yoke E, retaining nut F and washer G, torque tighten the nut to 400 Nm; 295 lbf ft. Check shaft end float which must not exceed 0.03 mm; 0.001 in.

* 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.

Note: Rotate shaft whilst measuring to fully seat bearings. Later assemblies use a flanged bolt in place of items F and G (the 4WD shaft has an internal thread). This bolt must be torque tightened to 395 Nm; 291 lbf ft.

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. 9803/3270

Issue 3*

Section F 68 - 3


Section F 68 - 3

Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON) continued 13

If the end float is incorrect, remove the output yoke E and bearing retaining circlip H. Note, if the end float is correct, it will still be necessary to remove the yoke - to fit the oil seal, see step 15.

14

Add or subtract shims J to obtain correct setting. Shims must be fitted between bearing outer race K and spacer L. Replace the circlip and yoke and check the shaft end float.

15

When the shaft end float is correct, remove the yoke and fit a new oil seal M.

16

Refit the output yoke E and tighten the new retaining nut F or flanged bolt A to 400 Nm; 295 lbf ft. Stake the nut to the shaft using a square ended staking tool, as shown at N.

17

Refit the hydraulic pipework and electrical connections.

Note: Later type 4 wheel drive covers P have no groove for circlip H but can be used provided the spacer L and circlip H are left out and the end float is checked using the following procedure. 18

Fit the 2/4WD unit to the transmission using a new gasket C. Fit mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft, do not apply JCB Threadlocker & Sealer at this stage.

19

Check shaft end float which must not exceed 0.03 mm; 0.001 in, make a note of the end float.

Note: Rotate shaft whilst measuring to fully seat bearings. 20

If the end float is incorrect, undo bolts D and remove casing.

21

Calculate the required thickness of shims J to give the correct end float. Shims must be fitted between bearing outer race K and casing P.

22

Refit the casing P and check the shaft end float.

23

When the shaft end float is correct remove bolts D apply JCB Threadlocker & Sealer to mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft.

24


25

Complete steps 15 to 17.

9803/3270

Issue 2

Section F

Transmission

Section F 68 - 4


68 - 4

Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON)

P

S173590

9803/3270

Issue 1

Section F 68 - 5

Transmission

Section F


68 - 5

Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON) Dismantling and Assembly

Inspection

Later type 2/4 wheel drive clutch assemblies have been revised in order to simplify the clutch pack setting procedure. The new clutch has no middle spacer, ie the actuating sleeve (item 15) is 12.2 mm; 0.480 inches longer. Detailed below is the correct dismantling and assembly procedure for the new clutch.

Carry out a visual inspection of the friction and counter plates.

Dismantling

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.

1

Remove the 2/4WD unit from the transmission - loosen the output yoke retaining nut before removal (see Note, Assembly, step 16).

2

Remove bearing 1, only if to be renewed.

3

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.

4

Pull off the 4WD output gear 5, together with its bearing 3, needle roller bearing 6 and thrust washer 4.

5

Using a suitable press, compress disc springs 8A, 8B and remove the circlip 7.

CAUTION: There is approximately 26700N (6000lbf) clamping force acting on the springs.

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.

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).

6

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.

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.

7

Remove the clutch drum retaining circlip 12 and support washer 13.

3

Place the disc spring 16 into the housing 21.

8

Remove clutch drum 14 and actuating sleeve 15 .

4

Position the actuating sleeve 15 onto the disc spring 16.

9

Remove disc spring 16.

5

Install the clutch drum 14 in the housing. Fit support washer 13 and drum securing circlip 12.

10

Remove the piston 17 and its spring steel ring 18.

6

11

Remove and discard piston O-rings 19 and 20.

Build up the clutch pack 11, installing friction plates and counter plates alternately, starting with a counterplate and finishing with a friction plate.

12

Remove the piston housing 21 only if necessary, the housing is a press fit on shaft 22.

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.

9803/3270

Issue 1

Section F 68 - 6

Transmission

Section F


68 - 6

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.

20

Refit the output yoke E and tighten the new retaining nut, or flanged nut, F to 400 Nm; 295 lbf ft, stake the nut to the shaft using a square ended staking tool, as shown at N.

Note: On later gearboxes, retaining nut F and washer G have been replaced by a flanged nut. Apply JCB Threadlocker and Sealer to threads and torque tighten to 395 Nm (291 lbf ft). 21

Refit the hydraulic pipework and electrical connections.

Note: Later type 4 wheel drive covers P have no groove for circlip H but can be used provided the spacer L and circlip H are left out and the end float is checked using the following procedure. 22

Fit the 2/4WD unit to the transmission using a new gasket C. Fit mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft, do not apply JCB Threadlocker & Sealer at this stage.

Fit the 2/4WD unit to the transmission using a new gasket. Apply JCB Threadlocker and Sealer to the mounting bolts, torque tighten the bolts to 56 Nm; 42 lbf ft.

23

Check shaft end float which must not exceed 0.03 mm; 0.001 in, make a note of the end float.

Fit the output yoke E retaining nut F and washer G, torque tighten the nut to 400 Nm (295 lbf ft).

24

If the end float is incorrect, undo bolts D and remove casing.

Note: On later gearboxes, retaining nut F and washer G have been replaced by a flanged nut. Torque tighten to 395 Nm (291 lbf ft).

25

Calculate the required thickness of shims J to give the correct end float. Shims must be fitted between bearing outer race K and casing P.

Check the shaft end float which must not exceed 0.03 mm (0.001 in), make a note of the end float.

26

Refit the casing P and check the shaft end float.

27

When the shaft end float is correct remove bolts D apply JCB Threadlocker & Sealer to mounting bolts D, torque tighten the bolts to 56 Nm; 42 lbf ft.

28


29

Complete steps 19 to 21.

See note after step 21. 15

16

Note: Rotate shaft whilst measuring to fully seat bearings.

Note: Rotate shaft whilst measuring to fully seat bearings. 17

18

19

If the end float is incorrect, remove the output yoke E and bearing retaining circlip H. Note, if the end float is correct, it will still be necessary to remove the yoke - to fit the oil seal, see step 19. Add or subtract shims J to obtain correct setting. Shims should be fitted between bearing outer race K and spacer L. Replace the circlip and yoke and check the shaft end float. When the shaft end float is correct, remove the yoke and fit a new oil seal M.

9803/3270

Issue 2

Section F


68 - 7

Section F 68 - 7

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, step 11).

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/in2 (13.8 bar).

5

If the pressure gauge reading is between 125 - 135 lbf/in 2 (8.6 - 9.3 bar) then the clutch is operating 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 be to the correct thickness). -test after checking for (and rectifying) assembly defects.

B A

S185720

9803/3270

Issue 1

Section F 69 - 1

Transmission

Section F 69 - 1


Torque Converter Removal See pages F/62-1 and F/62-2 for transmission/torque converter removal.

2

A

Replacing Ensure that flywheel face, drive plate, and hardware are clean and free from burrs or other surface imperfections.

1

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.).

S267910

B

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.

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.

9803/3270

S161470

3

2

1

A265990

Issue 1

Section F


70 - 1

Section F 70 - 1

S266880

A

C B

S159140

9803/3270

Issue 1

Section F


70 - 2

Section F 70 - 2

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.

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).

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: 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/in2) or damage to the converter seals will be caused.

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).

9803/3270

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.

Issue 1

Section F

Transmission

Section F

80 - 1

80 - 1

Collapsible Spacer - Assembly

4

When assembling the transmission, if the special tools listed in Service Tools, Section 1 or if the correct size solid spacer is not available fit a collapsible spacer using the procedure below.

3 S235760

1

Smear output shaft inner bearing with JCB HP Grease before refitting. Fit a new collapsible spacer over output shaft; assemble into rear (output) end casing.

2

After smearing with JCB HP Grease fit outer bearing followed by a new oil seal. Grease between seal lips before fitting. Assemble brake disc and NEW retaining nut with integral washer.

3

2

Tighten retaining 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 renewed. * Note: Due to ratio options some transmissions feature a larger diameter output gear Z. When removing the output shaft the gear may foul the transmission housing, preventing removal. For shaft removal procedure see Output Shaft (Larger Diameter Gear). 4

Finally stake nut into slot.

1

Z A310500

9803/3270

Issue 2

Section F 80 - 2

Transmission

Section F

Output Shaft (Larger Diameter Gear)

80 - 2

In the event of output gear A fouling the transmission housing (at position B) when attempting removal of the output shaft 1, proceed as follows: Note: The following procedure will be required when dismantling the transmission, and also after initial assembly, since the shaft will need to be removed when setting the end float.

C

To enable output shaft removal past the casing at B, the bearing inner cup/taper rollers 2 must first be removed from the shaft 1. 1

Press the output shaft 1 until the gear A contacts the housing at position B, take care not to damage the housing or gear A. Although the bearing inner cup/taper rollers 2 will be forced partially up the shaft 1, it will not be possible to remove them at this stage.

Note: If the output shaft is being removed after initial assembly, typically to set the end float, take extreme care to avoid damage to the outer bearing 3 and inner cup/taper rollers 2. Use only soft spacers such as aluminium at C, DO NOT USE HARDENED STEEL ITEMS SUCH AS SCREWDRIVERS.

1

C 2

3

A A318820

B

If the bearing is damaged a new bearing MUST be fitted. The tolerance difference between new bearings is expected to be less than the difference between the solid spacer sizes so changing a bearing should not affect the end float. 2

Pull the output shaft 1 up. Position suitable spacers C between the taper rollers 2 and bearing outer cup 3.

3

Push the output shaft down again, the inner cup/taper rollers 2 will be forced further up the shaft 1 allowing them to be removed.

4

If the inner cup/taper rollers 2 are still engaged on the shaft 1 repeat steps 2 and 3 using thicker spacers C.

5

With bearing inner cup/taper rollers 2 removed, the output shaft and gear can be lowered and tilted to one side, allowing the gear A to clear the housing and the shaft 1 to be removed.

9803/3270

Issue 1

S264530

P

Section F 100 - 1

Issue 2

217160

Transmission

C

L G M


D Q

J F

Z HE

K Z

Section F 100 - 1

9803/3270

General Description

A

B

141911

Electrically operated solenoid valves divert pressurised oil (provided by pump Q) to the selected clutch packs. A combined lever/swivel switch on the steering column actuates both gear ratio and direction solenoids.

Input clutch assembly B contains two hydraulically operated clutches; one clutch provides a forward low ratio drive and the other a forward high ratio drive. 3-position solenoid valve G, when energised, directs pressurised oil to either the forward low or forward high clutch.

Reverse drive is transmitted via constant meshing of spur gears Z.

* On machines with 6 solenoids fitted instead of 5, 3 position solenoid P, when energised, directs pressurised oil to either the layshaft or mainshaft. * On all transmissions with six solenoids the machine wiring is configured to select the neutral position for both the input (forward and reverse) and the mainshaft/layshaft clutch packs when neutral is selected on the machine forward reverse lever. * As machines with this new wiring configuration will have to fill two clutch packs instead of one when selecting forward or reverse, it is possible that at very low RPM for the transmission low pressure warning light to momentarily illuminate as the clutches fill. This is normal and is not detrimental to the transmission. The 2/4 wheel drive unit F also has a single clutch. When 4WD is selected, pressurised oil is directed to the 4WD clutch. When 2WD is selected a connection from the clutch to the transmission sump is made.

Transmission

The reverse clutch assembly C is similar to the input clutch assembly. It contains two hydraulically operated clutches; one clutch provides a reverse low ratio drive and the other a reverse high ratio drive. 3-position solenoid valve L, when energised, directs pressurised oil to either the reverse low or reverse high clutch.

Both the mainshaft and the layshaft assemblies have a single clutch each. Solenoid valve M, when energised, directs pressurised oil to the layshaft clutch. When there is no electrical power at the solenoid, the oil is directed to the mainshaft clutch.


The Powershift unit consists of a torque converter A, input clutch assembly B, reverse clutch assembly C, layshaft assembly E, mainshaft assembly D, 2/4 wheel drive clutch assembly F and a parking brake disc J mounted on splined output shaft K.

The torque converter 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 H.

Section F

The JCB Powershift is an electro-hydraulic transmission unit. Gear shifting and direction selection are controlled using multi-disc clutch packs.

100 - 2

9803/3270

General Description

The filter is used to prevent potential system contamination by filtering dirt particles.

Section F

100 - 2

Issue 2*

Transmission Powershift Transmission

Section F

Issue 1

100 - 3 S264610

Section F 100 - 3

9803/3270

Hydraulic Operation

Different combinations of engaged clutches give four gear ratios in forward and reverse drive. There must always be two clutches engaged before the machine will drive; 1) a direction ratio clutch, for instance forward low, and 2) a drive clutch (layshaft or mainshaft).

Excess oil from the maintenance valve flows through the casing to the torque converter. Oil enters the converter between the converter hub and the stator support, and leaves between the stator and the input shaft. Pressure in the converter is controlled by relief valve T which dumps oil from the converter line back to the sump. Oil from the torque converter flows out of the transmission unit to the external oil cooler V. From the cooler, the oil flows to pipe cluster W which distributes the oil to pass through the centre of all the clutches for lubrication purposes.

With 1st gear forward selected solenoid valves G and M are energised. The energised valves cause internal spools to move, which then divert pressurised oil to clutch packs B and E via internal galleries. The drive from the engine is then transferred via the engaged clutches and gears to the output flange (and finally to the road wheels). The following pages illustrate drive paths and which clutches are engaged for all 4 gear ratios. Restrictor orifices X in the feed lines to the solenoid valves modulate the pressure to the clutches, this ensures a smooth clutch engagement. Pressure from clutches not engaged will vent back to the sump via internal galleries and the solenoid spools.

Transmission

For the purpose of this description, clutches not used when 1st gear forward is selected are not shown.

The solenoid adaptor block houses the solenoid valves which are used to divert oil to the clutch packs.

In neutral, the flow of pressurised oil is blocked at the solenoid valves.


The illustration shows 1st gear forward selected, therefore the two engaged clutches will be forward low ratio clutch B and layshaft drive clutch E.

Oil from the pump Q is fed through an internal passage via the filter Y to the pressure maintenance valve R, which maintains a constant pressure to the solenoid valve adapter block S.

Section F

When the Powershift is operated multi-disc clutch packs are pressurised and engaged. The engaged clutch packs then transfer drive from the engine to the road wheels (via the torque converter A, input shaft H and drive shafts).

100 - 4

9803/3270

Hydraulic Operation

Section F

100 - 4

Issue 1

Section F


100 - 5

Powershift Drivepaths Item B1 B2 C1 C2 D E F G1 G2 L1 L2 M N *P

Section F 100 - 5

N

G2

Description Forward Low Ratio Clutch Forward High Ratio Clutch Reverse Low Ratio Clutch Reverse High Ratio Clutch Mainshaft Clutch Layshaft Clutch 2/4WD Clutch Forward Low Solenoid Forward High Solenoid Reverse Low Solenoid Reverse High Solenoid Layshaft Solenoid† 2/4WD Solenoid Mainshaft Solenoid

L1

S264530

G1

M

G2

L2

P

N

L1

* †Note: When 5 solenoids are fitted, solenoid valve M, when energised, directs pressurised oil to the layshaft clutch. When there is no electrical power at the solenoid, the oil is directed to the mainshaft clutch.

B2 B1 D

S217161

G1

M

L2

E

C2 F C1 9803/3270

S265580

Issue 2*

Section F

Transmission

Section F


100 - 6

100 - 6

Powershift Drivepaths Figure 1 - 1st GEAR FORWARD (4 Wheel Drive)

Figure 3 - 3rd GEAR FORWARD (4 Wheel Drive)

Clutches Engaged B1 - Forward Low Ratio E - Layshaft F - 2/4 wheel drive

Clutches Engaged B1 - Forward Low Ratio D - Mainshaft F - 2/4 wheel drive

Solenoids Active G1 - Forward Low Ratio M - Layshaft N - 2/4 wheel drive

Solenoids Active G1 - Forward Low Ratio N - 2/4 wheel drive * P - Mainshaft (6 solenoids only)

B1

B1

D

E F

F A265590

A265610

Figure 2 - 2nd GEAR FORWARD (4 Wheel Drive)

Figure 4 - 4th GEAR FORWARD (4 Wheel Drive)

Clutches Engaged B2 - Forward High Ratio E - Layshaft F - 2/4 wheel drive

Clutches Engaged B2 - Forward High Ratio D - Mainshaft F - 2/4 wheel drive Solenoids Active G2 - Forward High Ratio N - 2/4 wheel drive * P - Mainshaft (6 solenoids only)

Solenoids Active G2 - Forward High Ratio M - Layshaft N - 2/4 wheel drive

B2

B2

D

E F

F A265600

9803/3270

A265620

Issue 2*

Section F

Transmission

Section F


100 - 7

100 - 7

Powershift Drivepaths Figure 1 - 1st GEAR REVERSE (4 Wheel Drive)

Figure 3 - 3rd GEAR REVERSE (4 Wheel Drive)

Clutches Engaged C1 - Reverse Low Ratio E - Layshaft F - 2/4 wheel drive

Clutches Engaged C1 - Reverse Low Ratio D - Mainshaft F - 2/4 wheel drive

Solenoids Active L1 - Reverse Low Ratio M - Layshaft N - 2/4 wheel drive

Solenoids Active L1 - Reverse Low Ratio N - 2/4 wheel drive * P - Mainshaft (6 solenoids only)

D

E F

F

A265630

C1

A265650

C1

Figure 2 - 2nd GEAR REVERSE (4 Wheel Drive)

Figure 4 - 4th GEAR REVERSE (4 Wheel Drive)

Clutches Engaged C2 - Reverse High Ratio E - Layshaft F - 2/4 wheel drive

Clutches Engaged C2 - Reverse High Ratio D - Mainshaft F - 2/4 wheel drive Solenoids Active L2 - Reverse High Ratio N - 2/4 wheel drive * P - Mainshaft (6 solenoids only)

Solenoids Active L2 - Reverse High Ratio M - Layshaft N - 2/4 wheel drive

D

E

F

F

C2 9803/3270

A265640

C2

A265660

Issue 2*

Section F 100 - 8

Transmission

Section F


100 - 8

Clutch Operation The Powershift input clutch and reverse clutch assemblies operate in exactly the same manner as the forward/reverse clutch in the Syncro Shuttle transmission unit - please refer to page F/60-5. The Powershift mainshaft and layshaft assemblies each have a single clutch. Again, the principle of operation is similar to the description given on page F/60-5, ie the mainshaft/layshaft solenoid valve diverts pressurised oil to either the mainshaft clutch or the layshaft clutch.

2/4 Wheel Drive Operation The Powershift 2/4 wheel drive operation is similar to the description given on page F/60-6 (Syncro Shuttle transmission). However, please note that the Powershift 2/4 wheel drive solenoid valve is mounted on the solenoid block (shown at N), not on the 2/4 wheel drive housing (as is the case for Syncro Shuttle transmissions).

N N

S217161 S264530

9803/3270

Issue 2

Section F 101 - 1


Section F 101 - 1

Powershift Fault Finding - Introduction The Powershift fault finding procedures concern themselves with general problems normally associated with this type of transmission system, and so the layout is a 'Possible Cause and Remedy' type. Full flow, pressure and stall testing procedures for the Powershift transmission start on page F/111-1. * Before commencing with the fault finding procedure check the condition of the transmission oil. The type and condition of the oil is vital to the long term integrity of the gearbox. Check for the following transmission oil faults: * Incorrect oil type (must be JCB Special Transmission Fluid). Incorrect oil level (stop the engine before checking the gearbox oil level). Oil overheating. Oil contaminated with water. * Many types of faults can be caused by the above. In particular see the fault finding section on oil contaminated with water.

Powershift Fault Finding - Index Page No. Lack of Power

101 - 2

Low Mainline Pressure

101 - 2

High Stall Speeds (On All Clutches)

101 - 2

Low Stall Speeds (On All Clutches)

101 - 2

Low Converter Out Pressure

101 - 2

Low Pump Flow

101 - 2

High Converter Out Pressure

101 - 2

Low Lubrication Pressure

101 - 3

Low Clutch Pressure and/or Clutch Slipping

101 - 3

Overheating

101 - 3

* 4WD Cannot Be Engaged

101 - 4

* 2WD Cannot Be Engaged

101 - 4

* Transmission Oil Contaminated with Water

101 - 5

9803/3270

Issue 2*

Section F 101 - 2

Transmission

Section F


101 - 2

Powershift Fault Finding LACK OF POWER Possible Cause 1 Poor engine condition. 2 Low oil level. 3 Worn pump. 4 Torque converter damage. 5 Low mainline pressure. 6 Clutches slipping. 7 Internal leakage. 8 High stall speeds. 9 Low stall speeds. 10 Overheating * 11 Converter safety relief valve faulty. LOW MAINLINE PRESSURE Possible Cause 1 Worn pump. 2 Blocked suction strainer. 3 Pressure maintaining valve sticking/leaking. 4 Oil aerated (foaming).

5

Oil leak thru' 2/4WD circuit.

HIGH STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Damaged converter blades. 2 Clutches slipping. 3 Internal leakage. * 4 Converter safety relief valve faulty.

Remedy 1 Check and if necessary repair engine. 2 Top up system. 3 Check and if necessary repair or renew pump. 4 Check and if necessary repair or renew torque converter. 5 See fault 'Low Mainline Pressure'. 6 Check clutch pressures, check clutch piston rings. 7 Check internal cored galleries and the casting for porosity. 8 See fault 'High Stall Speeds (on ALL clutches)'. 9 See fault 'Low Stall Speeds (on ALL clutches)'. 10 See fault 'Overheating'. 11 Check and if necessary repair safety relief valve.

Remedy 1 Check and if necessary repair or renew pump. 2 Clean suction strainer. 3 Free off or renew valve. 4 a) Internal leakage (cored galleries) - inspect/repair transmission. b) Dirty suction strainer - clean strainer. c) High oil level - drain to proper level. d) Incorrect grade of oil - drain then refill with correct oil. 5 a) Check external pipework for 2/4WD circuit. b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel drive clutch fault finding procedure on page F/101-4.

Remedy 1 Check and if necessary repair or renew converter. 2 Strip, inspect and fit new clutch friction/counter plates. 3 Check internal cored galleries and the casting for porosity. 4 Check and if necessary repair safety relief valve.

LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 Poor engine condition. 2 Torque converter reaction member clutch slipping.

Remedy 1 Check and if necessary repair engine. 2 Check and if necessary repair torque converter.

LOW CONVERTER OUT PRESSURE Possible Cause 1 Low mainline pressure. 2 Converter internal leakage. 3 Converter relief valve faulty. 4 Restriction in converter feed.

Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check and if necessary renew converter. 3 Check and if necessary repair relief valve. 4 See item 10 in fault 'Overheating'.

LOW PUMP FLOW Possible Cause 1 Low oil level 2 Blocked suction strainer. 3 Worn Pump.

Remedy 1 Top up system. 2 Clean suction strainer. 3 Repair or renew pump

HIGH CONVERTER OUT PRESSURE Possible Cause 1 Oil cooler/lines blockage. 2 Converter in pressure incorrect. 3 Converter relief valve faulty.

Remedy 1 Clean cooler, free blockage. 2 Check converter in pressure correct. 3 Check and if necessary repair relief valve.

9803/3270

Issue 2*

Section F 101 - 3

Transmission

Section F 101 - 3


Powershift Fault Finding LOW LUBRICATION PRESSURE Possible Cause 1 Low mainline pressure 2 Oil cooler/lines blockage. 3 Ruptured lubrication line. 4 Converter internal leakage. 5 Converter relief valve faulty. 6 Leak at pump to case joint (indicated by low cooler flow) 7 Restriction in converter feed LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause 1 Low mainline pressure. 2 Worn pump. 3 Blocked restrictor orifice in solenoid valve block. 4

Clutch seals worn.

5 6

Clutch piston rings worn. Mechanical failure.

OVERHEATING Possible Cause 1 Low oil level. 2 High oil level. 3 Trapped or kinked hoses in cooler system. 4 Low converter out pressure and flow rate. 5 Oil cooler blockage. 6 Operating in wrong gear range usage. 7 Water system overheating. 8 Oil aerated (foaming). 9 Clutch piston(s) sticking on return stroke. * 10 Galleries A and B worn in pump mounting face (indicated by an excessively low pressure and flow on the converter out cooling line). 11 Leakage across pump mounting face and front case.

Remedy 1 See fault 'Low Mainline Pressure'. 2 Clean cooler, free blockage. 3 Repair line. 4 Check and if necessary renew converter. 5 Check and if necessary repair or renew relief valve. 6 Check and if necessary repair or replace as necessary. 7 See item 10 in fault 'Overheating'

Remedy 1 See fault heading 'Low Mainline Pressure'. 2 Check flow and if necessary repair or renew pump. 3 Remove solenoid(s) and clear restriction in solenoid valve block. 4 Confirm with a clutch leak test, if required renew clutch seals. 5 Confirm with a clutch leak test, renew piston rings. 6 Strip and rebuild clutch, renew parts as required.

Remedy 1 Top up system. 2 Drain oil to correct level. 3 Renew or repair hoses. 4 Repair or renew the converter relief valve. 5 Clean cooler. 6 Select correct gears to suit working conditions. 7 Rectify water system problems, eg radiator, cooler lines, low water level etc. 8 See fault 'Low Mainline Pressure', item 4. 9 Check and repair clutch piston(s) and seal(s). 10 Replace front housing (or rectify existing housing).

11 Check for damaged surface on both components and loose pump mounting bolts.

A

B

S154080

9803/3270

Issue 2*

Section F 101 - 4

Transmission

Section F


101 - 4

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 2 3 4 5 6

Check that the transmission oil level is correct. Check that the fuse for the 2/4WD circuit is intact. Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact. Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the 2WD position). Check that the mainline pressure is correct (see 'Low Mainline Pressure'). 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

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. in) 8.5 Leakage through piston ball valve, due to contamination or valve not seating correctly. 8.6 Clutch piston O-ring failed.

9

Defective 2/4WD clutch: 9.1 Worn friction/counter plates

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 8.5 Replace piston or rectify as required. 8.6 Replace clutch piston O-ring.

9

9.2 Mechanical failure of 4WD unit

9.3 Incorrect clutch pack end float. to

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 2.3 mm). Correct as required.

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

2/4WD solenoid permanently energised.

11

12

Piston ball valve blocked.

12

9803/3270

Check the 2/4WD relay and select switch, replace as necessary. Replace piston or rectify as required.

Issue 2*

Section F

Transmission

Section F 101 - 5


101 - 5

Fault Finding (continued) Transmission Oil Contaminated with Water Carefully inspect the transmission 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 transmission 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. Possible Cause

Remedy

1

Water ingress during filling/topping up.

Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

2

Missing/incorrect dipstick, damaged filler tube.

Renew missing/incorrect/damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

3

Machine operated in deep water.

Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

4

Oil cooler failure.

Remove, inspect, test oil cooler. Renew if applicable. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

5

Gearbox or bevel gearbox casings damaged.

Inspect, renew damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

6

Gearbox oil circuit pipes/hoses damaged.

Inspect, renew damaged components. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

Gearbox faults caused typically by water contamination and other factors related to the transmission oil:

1

Fault

Possible Cause

Remedy

Pressurisation of transmission casing - Dipstick blows out/oil leaking from dipstick tube.

Water in oil combined with heat from torque converter causes steam.

Replace/renew dipstick. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

Gearbox over filled with oil.

Drain the oil level to the correct level, see Routine Maintenance - Checking Transmission Oil Level.

2

Clutch Failure - Friction Lining Separation.

Water ingress.

Renew friction plates. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

3

Clutch Failure - Clutch Piston Seizing.

Water ingress causing nylon components to swell and stick when hot.

Carry out flushing procedure. Refill with JCB Special Transmission Fluid. Note: If after a period of service without water contamination seizing still occurs, renew piston.

Overheating transmission oil.

See Fault Finding - Overheating.

Water ingress.

Fit new bearings. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

4

Badly worn/noisy bearings.

Insufficient lubrication.

9803/3270

Issue 1

Section F

Transmission

Section F 102 - 1


102 - 1


C E

P

N B S264710 A258620

9803/3270

Issue 1

Section F

Transmission

Section F 102 - 2


102 - 2

Removal and Replacement (cont’d)

12

Using the trolley jack, lower the transmission and engine to gain access to the top flywheel housing to engine block retaining bolts J - do not remove bolts at this stage.

Park the machine on firm level ground.

! WARNING

13

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 transmission oil cooler at the transmission unit, shown at B and N.

14

Disconnect the transmission solenoid valve flying lead connectors A. Label the connectors for identification when refitting.


15

Put a support under the engine as shown at G to prevent it from dropping when the transmission is removed.

16

Remove the flywheel housing to engine bolts J.

17

Manoeuvre the transmission with the torque convertor clear of the engine housing.

18

Lower the trolley jack and pull the transmission and torque convertor clear of the machine.

GEN 1-1

Removal 1

Rest the bucket on the ground and raise the stabiliser legs sufficiently to allow room for the transmission to be pulled clear. Block/support the machine.

2

Drain the transmission system, see page 3/13-1.

3

Remove the engine bonnet, see page 3/4-1.

4

Remove the engine fan retaining bolts P (4 off) and remove the fan, see note 1.

Note 1: At a later stage the transmission is tilted to give access to retaining bolts, if the fan is not removed at this stage it will foul. 5

Remove rear axle drive shaft bolts E.

6

Remove 4WD shaft bolts F (use tool 892/00822).

7

Disengage the parking brake clevis at the parking brake caliper and remove outer cable retaining circlip as shown at C.

8

Remove the transmission dipstick tube and filter, shown at M.

9

Remove the access bung/plate at the bottom of the flywheel housing. Through the access hole, loosen and remove the torque convertor to engine flywheel retaining bolts Q.

10

Support the transmission with a trolley jack attachment as shown at H (see Section 1, Tools), refer to note 2.

Note 2: The Powershift weight distribution is unbalanced. It is very important that the transmission is securely supported before attempting to complete the removal procedure. The trolley jack attachment prevents the transmission from moving side to side AND front to back when being removed. 11

Replacement Replacement is a reversal of the removal procedure. The solenoids should have been labelled before removing connecters, however page F/100-5 identifies the solenoids and the correct electrical connections. Set the parking brake cable as described on page 3/7-1. If the parking brake caliper has been removed reset central to the parking brake disc, see page G/22 - 4. Set the torque converter as described on page F/69 - 1. Fill the transmission with the specified amount of JCB Special Transmission Fluid (see page 3/1-1 for capacity).

Torque Settings Item E F J K P Q

Nm 118 79 98 237 25 44

kgf m 12 8 10 24 2.5 4.5

lbf ft 87 58 72 175 18 32

Make sure that the weight of the transmission is supported by the trolley jack and remove the transmission mounting bolts K.

9803/3270

Issue 1

Sheet 1 of 3

Torque Figures and Assembly Notes

1

1

23

Torque Settings

1 1 9 13

12

19 20

Nm

lbf ft

kgf m

1

56

41

5.7

2

8 - 10

5.9 - 7.4

0.8 - 1.0

3

203

150

20.7

4

102

75

10.4

5

5-8

4 - 5.9

0.6 - 0.8

6

10

7.4

1.0

7

85

63

8.6

8

20 - 24

14.8 - 17.7

2.0 - 2.4

9

28

20

2.8

10

12

8.8

1.2

11

400

296

40

Assembly Notes

14 22

Notes Bearings to be lightly oiled before setting and must be rotated whilst being set.

13

Select shims to give input shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

14

Select shims to give mainshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

15

Select shims to give layshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

12 1

12

21

11 12

15

21 12

9

A264570

103 - 1

Issue 2*

.....continued

16

Section F

Item 12

Transmission

12

Item


18

23

Section F

Section Views and Torque Figures

103 - 1

9803/3270

* PS700

Assembly Notes (continued)

1

9

16

Select shims to give 4WD output shaft to give 4WD output shaft end play of 0.03 mm (0.001 in) maximum.

17

Select shims to give reverser shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

* 17A

On later transmissions the reverser cover 17A is replaced by an inspection plug and requires a different procdure, see Summary of Changes.

18


* 19

The procedure for tightening the stake nut varies depending on whether a solid spacer or collapasible spacer is fitted. See Assembly procedure for details.

20

Assemble with tapped extraction holes facing out.

21

Measure end float of pressure plate. Free movement on plates to be :

4 7

9

8 10

1 1

5 9

1 1 17A 9 17 1

6

A264580

Fit pressure

shim

plates, between plate and circlip. .....continued

103 - 2

Issue 2*

1

Section F

1

Mainshaft clutch - 2.2 to 3.5 mm (0.087 to 0.138 in). Layshaft clutch - 1.93 to 3.2 mm (0.075 to 0.126 in).

Transmission

Notes


Item

Section F

Sheet 2 of 3

Section Views and Torque Figures (continued)

103 - 2

9803/3270

* PS700

Assembly Notes (continued) Item

Notes

22

Pack bearing with grease before assembly.

1 9

* 23

4 1

9 9

Transmission

1

The transmission should be rebuilt with a solid spacer, which is the prefered option. However in the absence of the special tools required or of a solid spacer, a collapsible spacer may be fitted.


4

Section F

Sheet 3 of 3

103 - 3

9803/3270

PS700 Section Views and Torque Figures (continued)

1

103 - 3

Issue 2*

A264590

Section F

3

Section F 104 - 1

Transmission

Section F 104 - 1


Powershift - Dismantling Refer also to ‘Section Views and Torque Figures’ at the beginning of the transmission section.

1

Make sure all the oil has been drained from the casing by removing drain plug. Drain the oil into a suitable container.

2

Remove and discard the oil filter.

3

Remove the temperature switch.

3

2 1

S217450

4

Unscrew bolts and withdraw the torque converter pump assembly.

5

Remove and discard the pump sealing ring.

5 4

6

Separate pump components.

7

Remove and discard oil seal from pump housing.

7

9803/3270

6

221020

Issue 1

Section F 104 - 2

Transmission

Section F 104 - 2


Powershift - Dismantling (continued) 8

Unscrew cap screws and remove the reverse high/low clutch solenoid valve.

9

Unscrew cap screws and remove the mainshaft/layshaft clutch solenoid valve.

10

Unscrew cap screws and remove the input (forward) high/low clutch solenoid valve.

10

9

8

Refer to Solenoid Valve, Powershift Transmission for the solenoid valve dismantling and assembly procedure.

S264530

11

Unscrew nut on top of the 4 wheel drive solenoid valve body. Remove the valve.

12

Remove the 4 wheel drive solenoid valve spool.

13

Remove the 4 wheel drive assembly oil feed pipe.

14

Unscrew 16 bolts and remove the solenoid adaptor block.

15

Remove and discard the solenoid adaptor block gasket (not shown).

16

14

16 11

12

Unscrew plug and withdraw pressure maintenance valve spool and spring.

13 S217170

17

Unscrew 11 bolts and remove the 4 wheel drive unit with its clutch assembly. See 2/4 Wheel Drive, Syncro Shuttle Transmission for dismantling and assembly procedures.

17

Note: If the flywheel housing flange is the SAE (circular) type, it will be necessary to remove the SAE flange before the 4WD clutch unit can be removed - refit the SAE flange after removing the 4WD clutch unit. Also, If the 4 wheel drive unit is to be dismantled, then hold the brake disc with tool 992/04800 and loosen the 4 wheel drive flange retaining nut prior to removing the complete 4 wheel drive assembly. S217180

9803/3270

Issue 1

Section F 104 - 3

Transmission

Section F 104 - 3



Position transmission vertically, standing on face of flywheel housing as shown.

20

CAUTION: The Powershift transmission weighs approximately 236 kg (520 lb) when dry. A crane must be used to manoeuvre the transmission into a vertical position. 19

Remove the torque converter relief valve ball, spring and sealing washer.

20

Remove 4 bolts and remove the layshaft end cap.

21

Remove the layshaft shim and 'O' ring.

22

Unscrew 20 bolts and lift off rear (output) end casing.

21 18

Note: Make sure that internal components remain seated in the front casing. If necessary, rotate the brake disc back and forth slightly to dislodge the internal components.

22

19

S217190

9803/3270

Issue 2

Section F 104 - 4

Transmission

Section F 104 - 4



Note the three 'O' rings (fitted next to the input and reverse clutch assemblies).

Note: For reference, the clutch assemblies are identified as follows: A = Reverse Clutch B = Mainshaft C = Layshaft D = Input Clutch 24

D

Tilt and lift out the layshaft assembly C.

B

C

See Layshaft, Dismantling and Assembly, Powershift Transmission for dismantling and assembly of the layshaft and its clutch assembly. 25

This step requires the help of an assistant. Have the assistant SLIGHTLY lift and tilt both the mainshaft and input clutch; then tilt and lift out the reverse clutch A.

23 See Input Clutch and Reverser Clutch, Dismantling and Assembly, Powershift Transmission for dismantling and assembly of the reverse clutch assembly. 26

Slightly lift the input clutch and at the same time tilt and lift out the mainshaft B. See Mainshaft, Dismantling and Assembly, Powershift Transmission for dismantling and assembly of the mainshaft and its clutch assembly.

27

A

Lift out the input clutch D. See Input Clutch and Reverser Clutch, Dismantling and Asembly, Powershift Transmission for dismantling and assembly of the input clutch assembly.

28

A264740

Unscrew 11 bolts and remove the flywheel housing.

28

S217220

9803/3270

Issue 1

Section F 104 - 5


Section F 104 - 5


Whilst holding brake disc with tool 992/04800, unscrew output shaft nut. Support output shaft from beneath and lift off brake disc. Remove the output shaft assembly.

30

Prise out oil seal and discard.

31

Remove outer taper roller bearing

32

Remove and discard spacer and shims.

33

Using a suitable puller, withdraw output shaft inner bearing.

Note: If required, the new type parking brake bracket A can be removed at this stage, before removing mark the position of the bracket relative to the casing.

29

30 31 A

32 33 29

S217201 S217202

34

Remove two bolts and withdraw the strainer. Discard the strainer gasket. Finally, after repair and renewal of parts, make sure casings and parts have been thoroughly cleaned using suitable solvents before starting the assembly procedures.

34 S217230

9803/3270

Issue 3

Section F 104 - 6

Transmission

Section F 104 - 6

Powershift

Assembly 1

Before starting the assembly of the powershift transmission make sure that all casings and components have been thoroughly cleaned with a suitable solvent. When assembling, smear bearings with JCB HP Grease. Renew all 'O' rings, seals and gaskets. Finally, please remember that dirt in the transmission system will cause damage to the powershift and its associated parts.

* 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. 2

Using a new gasket, install suction strainer. Apply JCB Threadlocker and Sealer to bolts and tighten to 10 Nm (7 lbf ft).

2

3

Remove the mainshaft end spacer. Remove and discard the two 'O' rings. DO NOT fit 'O' rings at this stage (see note), refit the spacer.

Note: This is a preparatory step for setting the mainshaft end float. At a later stage it will be necessary to remove the end spacer so that shims can be fitted to correct end float inaccuracies. If the 'O' rings are left on at this stage, the seal prevents the spacer from being removed. New 'O' rings are fitted once the correct mainshaft end float has been established.

3

End spacers have extraction holes to assist removal.

4

S217230

Fit the flywheel housing. Fit bolts and torque to 56 Nm (42 lbf ft).

S217240

4

Note: The flywheel housing is temporarily fitted at this stage so that the transmission can be stood vertically (for assembling internal components). DO NOT apply JCB Threadlocker and Sealer to the bolts at this stage or bond mating faces.

S217220

9803/3270

Issue 3*

Section F 104 - 7

Transmission

Section F 104 - 7

Powershift

Assembly (cont’d) Note: If the new type parking brake mounting bracket A has been removed it must be fitted at this stage in the position as marked during dismantle, see page G/22-10 for torque figures. When building a transmission with a solid spacer a 15mm (0.50in) diameter hole will have to be drilled at B to enable the fitting of the tool for checking the end float. 5

a

Lightly oil output shaft inner bearing and cup P and fit to output shaft.

10

S

RPM x

R

5

Note: The gearbox may have been fitted with either a collapsible spacer N (early machines) or solid spacer N (later machines). The preferred option is a solid spacer, fitting of which is described in the following procedure. However, in the absence of the special tools required or of a solid spacer, a collapsible spacer may be fitted as described under Collapsible Spacer - Assembly on page F/80-1.

A

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.

N P

S217202

S217201

6

a Fit special tool sleeve A which temporarily replaces disc brake 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.

C B

D

The correct bearings are fitted, check parts catalogue. The solid spacer N is 13.70 mm.

A

b Fit special tool support pillar C so that the fork end engages in special tool nut B, tighten bolt D.

S265900

9803/3270

Issue 4

Section F

Transmission

Section F 104 - 8

Powershift

104 - 8 Assembly (cont’d) *7

a

E

Fit dial test indicator E (DTI).


To select the right size spacer, subtract the end float obtained at step 7b 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 13.70 Subtract end float 0.41 Total 13.29 Subtract tolerance & preload Result 13.17

F

0.12 S265910

n s

Use next smallest spacer ie. 13.15 If the ‘Result’ measurement is outside the spacer kit range use a collapsible spacer, see Collapsible Spacer Assembly page F/80 - 1.

*8

d

Remove sleeve A and fit correct size spacer. 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 the rolling torque is too low, fit the next smaller size spacer.

a

Remove nut B and sleeve A. Fit new oil seal S, grease between seal lips before fitting. Assemble brake disc/flange (the disc/flange may be a tight fit).

b

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 not exceed a maximum of 2.0 Nm (1.5 lbf ft) when 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. c

B A

S265900

T

Finally stake nut T into slot.

S 9803/3270

A273410

Issue 2*

Section F 104 - 9

Transmission

Section F 104 - 9

Powershift

Assembly (cont’d) 9

Position transmission vertically, standing on face of flywheel housing as shown. Grease piston ring seal and smear pump end bearing with JCB HP Grease, then carefully lower input clutch into casing.

9

S217250

10

Assemble two halves of casing together and tighten bolts to 56 Nm (42 lbf ft).

10 Note: Assembling the case halves at this stage is a temporary arrangement to enable measurement of the input clutch shaft end float. DO NOT apply JCB Threadlocker and Sealer to the bolts at this stage or bond mating faces. Note: To prevent damaging input shaft piston ring seals, it is permissible to remove the seals prior to assembling case halves. However this is applicable only whilst measuring input shaft endfloat. REFIT THE SEALS BEFORE FINAL ASSEMBLY. S217260

11

Position transmission horizontally and measure the end float of the input clutch shaft, which should be 0.03 to 0.08 mm (0.001 to 0.003 in).

Note: Rotate the shaft whilst measuring to seat bearings fully.

S217270

12

Separate two halves of casing and add or subtract shims fitted beneath the bearing outer race (in the rear(output) case) to correct input clutch shaft end float. Repeat steps 10 and 11 to recheck the endfloat. When correct end float has been achieved, remove the input clutch and refit piston ring seals removed in step 10.

Note: Production machines have the shim fitted in the front case; however, when servicing the Powershift, it is permissible to fit shims in the rear case as shown.

12 S217280

9803/3270

Issue 2

Section F 104 - 10

Transmission

Section F 104 - 10

Powershift


Fit the input clutch V and the mainshaft Q simultaneously into the front case as shown. Before fitting make sure that piston ring seals have been lightly greased, and both the input clutch and mainshaft taper roller bearings have been smeared with JCB HP Grease.

14

This step requires the help of an assistant. Have the assistant SLIGHTLY raise and tilt the input clutch and mainshaft, whilst the assistant is holding the two units, fit the reverse clutch P.

15

Smear the layshaft taper roller bearing with JCB HP Grease and fit the layshaft assembly T to the front case.

V

T

Q

P

The clutch assemblies should now be installed in the front case as shown in the illustration. Make sure that all bearings are fully seated, and that the relevant gears have meshed correctly. 16

Using two small rods (screwdrivers) align the friction/counter plates of the mainshaft clutch.

17

Fit three new 'O' rings in the front case. Smear the 'O' rings with grease to hold in position.

18

Apply JCB Multi-gasket to front case mating face. Prior to fitting the rear (output) case, make sure all bearings have been smeared with JCB HP Grease. Make sure all piston ring seals are in good condition and have been smeared with grease.

S217290

17

16

20

Note: Do not apply an excessive amount of JCB multigasket around 'O' rings (see step 17), too much can dislodge the 'O' rings. 19

S217300

Make sure the friction/counter plates in the mainshaft clutch are aligned (see step 16).

20

Carefully lower rear (output) case into position, taking care to align output gear splines with the mainshaft clutch friction/counter plates. Apply JCB Threadlocker and Sealer to bolts and torque to 56 Nm (42 lbf ft). 20

Using a new gasket fit the layshaft end cap and shims, torque tighten retaining bolts to 56 Nm (42 lbf ft).

Note: Fitting the layshaft end cap at this stage is a temporary arrangement to enable measurement of the layshaft end float. Do not apply JCB Threadlocker and Sealer to retaining bolts at this stage. Note: Take care not to damage the gasket as it must be used for final assembly.

19 S217310

9803/3270

Issue 2

Section F 104 - 11

Transmission

Section F 104 - 11

Powershift


21

Position the transmission horizontally. Unscrew bolts and remove the flywheel housing.

S217220

22

Measure layshaft end float, which should be 0.03 to 0.08 mm (0.001 to 0.003 in). Rotate the shaft (use the brake disc) whilst measuring to seat bearings fully.

X

Note: Access to the layshaft end face is gained through 4 wheel drive bolt hole X, as shown. Note: When measuring the endfloat, move the layshaft by hand, gaining access through the 4 wheel drive housing.

S217330

23

Remove the layshaft end cap and add or subtract shims to give correct end float. Fit shims between outer race and layshaft end cap.

24

Prior to final fitting of the layshaft end cap, fit a new 'O' ring in the rear case. Smear the 'O' ring with grease to hold in position.

25

Smear the layshaft outer bearing with JCB HP Grease. Refit the layshaft endcap with its new gasket. Apply JCB Threadlocker and Sealer to bolts and torque tighten to 56 Nm (42 lbf ft).

25

24

23

S217340

9803/3270

Issue 2

Section F 104 - 12

Transmission Powershift

Section F 104 - 12


Install tool 892/00295 over the mainshaft end bearing and spacer, as shown. Tighten securing bolts to 56 Nm (42 lbf ft).

26

S217350

27

Measure mainshaft end float which should be 0.03 to 0.08 mm (0.001 to 0.003 in). Rotate mainshaft (use the brake disc) whilst measuring in order to seat bearings fully.

Note: Screw a suitable bolt into the drilled and tapped hole in the end of the mainshaft and use the bolt to move the mainshaft back and forth when setting the endfloat.

S217360

28

Add or subtract shims to correct the end float. The shims must only be fitted between the bearing outer race and spacer. When the correct end float has been established - REFIT THE SPACER WITH NEW 'O' RINGS A (see note).

Note: In step 3 (Assembly) the mainshaft end spacer was fitted without its 'O' rings so that it could be readily removed. Fit the spacer with the extraction holes facing towards you.

28 A

S217370

9803/3270

Issue 2

Section F 104 - 13

Transmission

Section F 104 - 13

Powershift


Unscrew reverse clutch end cap bolts and remove the cap.

29

S217380

30

Install tool 892/00825 together with a new gasket in place of reverse clutch end cap. Tighten bolts to 56 Nm (42 lbf ft).

Note: Take care not to damage the gasket as it must be used for final assembly.

30

S217390

31

Measure reverse clutch shaft end float which should be 0.03 to 0.08 mm (0.001 to 0.003 in). Rotate reverse clutch (use the input shaft) whilst measuring in order to seat bearings fully.

Note: Screw a suitable bolt into the drilled and tapped hole in the end of the forward clutch shaft and use the bolt to move the shaft back and forth when setting the endfloat.

S217400

32

Add or subtract shims to correct the end float. The shims must only be fitted between the bearing outer race and spacer A.

32

A

S217410

9803/3270

Issue 2

Section F 104 - 14

Transmission

Section F 104 - 14

Powershift


Smear the reverse clutch bearing with JCB HP Grease. Fit the reverse clutch end cap and gasket, apply JCB Threadlocker and Sealer to bolts and torque to 56 Nm (42 lbf ft).

33

S217380

34

Using a new gasket, install the 4 wheel drive unit. Apply JCB Threadlocker and Sealer to bolts and tighten to 56 Nm (42 lbf ft).

34

S217420

35

Make sure all bearings have been lubricated with JCB HP Grease. Apply JCB Multi-gasket to mating face of flywheel housing. Fit the flywheel housing, apply JCB Threadlocker and Sealer to bolts and torque to 56 Nm (42 lbf ft).

36

Fit a new pump sealing ring.

37

Assemble pump (if dismantled). 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). Use a new pump housing seal A.

35 36 37

A 38

S217430

Fit torque converter relief valve ball and spring. Make sure that the larger diameter of the spring is located securely over the spigot on the plug. Use a new sealing washer, then fit and tighten plug.

S217440

9803/3270

Issue 2

Section F 104 - 15

Transmission

Section F 104 - 15

Powershift


Using a new gasket, fit the solenoid adaptor block to the casing. Apply JCB Threadlocker and Sealer to bolts and tighten to 28 Nm (21 lbf ft).

40

Assemble pressure maintenance valve spool and spring into adaptor block. Fit and tighten plug. Do not overtighten as damage to the aluminium housing could result.

41

Renew 'O' ring and fit the 4 wheel drive solenoid spool.

42

Install the 4 wheel drive solenoid valve body. Apply JCB Threadlocker and Sealer to the spool thread, fit the retaining nut and torque to 7 Nm (5 lbf ft).

40

39

42

41

CAUTION: Over tightening the retaining nut will cause valve failure. 43

Fit the 4 wheel drive assembly oil feed pipe (support bracket not shown).

43 44

Mount the forward high/low clutch solenoid valve onto adaptor block. Fit cap screws and tighten to 5 Nm (4 lbf ft).

45

Mount the mainshaft/layshaft clutch solenoid valve onto adaptor block. Fit cap screws and tighten to 5 Nm (4 lbf ft).

46

Mount the reverse high/low clutch solenoid valve onto adaptor block. Fit cap screws and tighten to 5 Nm (4 lbf ft).

44

45

S217170

46

Note: The mounting holes will only align when the solenoid valve has been positioned correctly on the adaptor block.

S217160

9803/3270

Issue 3

Section F

Transmission

Section F 104 - 16

Powershift

104 - 16

Powershift -Assembly (continued) 48

B

When applicable, fit the electronic speed sensor. Note: Some machines are fitted with a spacer A. The thickness of spacer A is dependant on the number of teeth on the transfer gear. If a new spacer is fitted make sure it is the correct thickness. Fitting incorrectly will cause the speed sensor to be damaged or inoperable.

A 47

Spacers must be fitted as follows: Transfer Gear Teeth 45T 46T 47T

Gearbox Ratio

Spacer A

Standard Low Ratio Extra Low Ratio

No spacer fitted 3.6 mm thick spacer 5.1 mm thick spacer

47

Fit new ‘O’ ring.

48

Locate speed sensor together with the correct spacer A (when applicable). Fit retaining screw. A297050

Note: Some machines have no speed sensor and incorporate a blanking plug B. If the plug has been removed, fit a new ‘O’ ring 47 before replacing the plug. 49

50

51

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.

Fit the drain plug with a new sealing washer - torque tighten to 203 Nm (150 lbf ft).

51

49

Refit the temperature switch.

50

S217451

9803/3270

Issue 1

Section F 105 - 1


Section F 105 - 1

Polytetrafluoroethene (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

9803/3270

Issue 1

Section F


106 - 1

Section F 106 - 1

Solenoid 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 10 to 15

9803/3270

kgf m 1 to 1.5

lbf ft 8 to 10

Issue 1

Section F 107 - 1

Transmission

Section F


107 - 1

PS700 - Input Clutch & Reverser Clutch - Dismantling Note: The following illustrations show a typical clutch, the procedures are the same for the input clutch and the reverser clutch. The only visual difference will be the diameter of the gear and splined hub assemblies. 1

1



S232720

2

Loosen the clutch end bearing by tapping the assembly on a piece of wood as shown. Remove the bearing using pullers.

2

S232730

3

Remove the bearing, thrust washer and plastic type washer.

4

Withdraw the gear and splined hub assembly with the needle roller bearing.

3

4 S264660

5

Remove plastic type washer and thrust washer.

6


7


5

6 7

S217540

9803/3270

Issue 2

Section F 107 - 2

Transmission

Section F


107 - 2

PS700 - Input Clutch & Reverser Clutch - Dismantling (cont’d) 8


9

Remove last counter plate.

10

Remove disc spring assembly.

Note: The disc spring is assembled within a liner (not shown) to protect the hub support spline.

8

9 10

S232741

11

Position clutch assembly in press to compress piston spring then remove circlip.

11

Note: If no press is available, spring compressor tool 892/00916 can be used.

12

12

Lift off spring retaining plate.

13

13

Remove spring. S145000

S264670

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. Make sure the piston liner is secure. The liner must be a tight fit on the piston.

16

Repeat steps 2 to 15 to dismantle the opposite clutch.

15

S264720

9803/3270

Issue 2

Section F 107 - 3

Transmission

Section F


107 - 3

PS700 - Input Clutch & Reverser Clutch - Assembly 1

Fit new 'O' rings onto the piston and shaft, lubricate with oil then press piston fully into bore of clutch housing.

* Note: The original plastic piston A must be replaced by an aluminium piston. Ensure the outer ‘O’ ring seal is correctly seated in its groove. Check that the ball valve X is seating correctly.

X A

1

A264721 A264721

2

Install the piston spring, make sure the spring seats in the piston.

3


4

Position the clutch assembly in a press with cutaway tube Y, compress spring and secure with circlip. If a press is not available use spring compressor tool 892/00916 and fit circlip.

Y

4 3 2

S145000

S254670

*5

Inspect the disc spring for signs of contact at with the piston or plate support carrier or loosening in the crimped housing. If there is contact, or the housing is damaged renew the disc spring assembly. Fit the disc spring assembly. Fit the assembly so that the outer diameter curves away from the clutch piston.

7

6 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.

5

S232741

* Note: When assembling the friction and counterplate ensure they are located to clear the oilways in the clutch body. 9


10


10

9

S217580

9803/3270

Issue 3*

Section F 107 - 4

Transmission

Section F


107 - 4

PS700 - Input Clutch & Reverser Clutch - Assembly (cont’d) 11


Note: The shim has teeth on the outside diameter; the teeth prevent it from spinning during operation.

S217590

12

Fit thrust washer and plastic type washer.

12

S217600

13

Fit gear and splined hub assembly.


Fit needle roller bearing.

15

Fit plastic type washer and thrust washer.

15 14

13

S232370

16

Smear the clutch end bearing with JCB HP Grease and press the bearing onto shaft.

17

Fit piston ring seals.

18

Repeat steps 1 to 16 for the opposite clutch, make sure that the opposite clutch end taper roller bearing is packed with grease.

17 16

S232720

9803/3270

Issue 2

Section F

Transmission

Section F


107 - 5

107 - 5

PS 750 - Input & Reverser Clutch - Dismantling

20

21

19

8

7

8

12

9

5 4

4 6

18 17

1

2

15

16

3 14 14

11 15

16 20

17 18 8 19

12

13 10 21 7 8 9 10 11 22

13 23 26

24 6

24

25

A324730

9803/3270

Issue 1

Section F

Transmission

Section F


107 - 6

107 - 6

PS 750 - Input & Reverser Clutch - Dismantling 1

Carefully remove piston ring seal 1.


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.

2

Remove the clutch end bearing 2 and gear 3, using a collet tool and press.

14

Remove and discard piston and shaft ‘O’ rings 20 and 21.

3

Remove the needle roller thrust bearing and thrust washer 4.

15

To dismantle the opposite clutch, carefully remove piston ring seals 22.

4

Withdraw the gear and splined hub assembly 5 with the needle roller bearing 6.

16

Loosen the clutch end bearing 23 by tapping the assembly on a piece of wood, then remove end bearing using puller.

5

Remove needle roller bearing thrust washer 7 and thrust washers 8.

17

Remove thrust washer needle roller thrust bearing 25 and thrust washers 24.

18

Withdraw the gear and splined hub assembly 26 with the needle roller bearing 6.

19

Repeat steps 5 to 15.

6

Remove friction/counter plates retaining circlip 9.

7

Remove pressure end plate 10 and shim 11, if fitted.

8

Remove the friction plates 12 and counter plates 13. Keep them together in sets, DO NOT mix the plates with those from other clutches.

9

Remove disc spring assembly 14.

10

%

Position clutch assembly in press, with a cut away tube compress piston spring then remove circlip 15.

Lift off spring retaining plate 16.

12

Remove spring 17 and oil baffle 18.

13

Knock the clutch shaft on a piece of aluminium (or wood) to remove the piston 19.

9

%

S259310

11 12 9 13 14 21 17

5 4 2

3

6

1

7

9803/3270

B A

If a press is not available use compressor spring tool A (892/00916) to remove circlip 15. Refit circlip 9 and locate the feet of the tool underneath the circlip. Fit ‘C’ shaped plate over the spring retaining plate, use two bolts B to relieve spring tension and remove circlip 15. 11

B

8 15 16 19 18 20

26

25 23 24 22

A324760

Issue 1

Section F 107 - 7

Transmission

Section F


107 - 7

PS 750 - Input & Reverser Clutch - Assembly Visually inspect the friction and counter plates:

9

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.

Using a dial test indicator as shown, measure the end float of the pressure end plate, which should be 1.90 to 2.50 mm (0.075 to 0.098 in). To adjust the end float, there is a choice between a 6.0mm (0.23in) or 6.5mm (0.25in) pressure end plate 10 with either a shim 11 or extra counter plate 13 between circlip 9 and pressure end plate 10.

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 14 to avoid marking or damage, which could result in stress cracking. If in doubt fit a new disc spring. 1

Fit new 'O' rings 21 and 20, lubricate with oil then press piston 19 fully into bore of clutch housing.

2

Fit the oil baffle 18, piston spring 17, make sure the spring seats in the piston.

3

Fit the spring retaining plate 16.

4

Compress spring and secure with circlip 15.

5

Fit the disc spring assembly 14. 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 13, then fit one friction plate 12 followed by one counter plate. Continue fitting alternate friction and counter plates, finishing with a friction plate.

7

Fit the pressure end plate 10. Make sure the teeth are not aligned with the lubrication slots in the housing. Do not fit shim 11 at this stage.

8

Fit the clutch friction/counter plates retaining circlip 9.

S217590

10

Fit thrust washers 8 and needle roller bearing thrust washer 7.

11

Fit gear and splined hub assembly 5.


Fit needle roller bearing 6.

13

Fit needle roller bearing thrust washer and thrust washer 4.

14

Smear the clutch end bearing with JCB HP Grease and press the gear 3 and bearing 2 onto the shaft.

15

Fit piston ring seal 1, see (PTFE) Piston Ring Seal Fitting Procedure.

16

Repeat steps 1 to 13 for the opposite clutch.

17

Press the gear 26 onto the shaft.

Note: Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver).

9803/3270

12

Fit needle roller bearing 6.

18

Fit needle roller bearing thrust washer 24 and thrust washer 25.

19

Smear the clutch end bearing with JCB HP Grease and press bearing 23 onto the shaft.

20

Fit piston ring seals 22, see (PTFE) Piston Ring Seal Fitting Procedure.

Issue 1

Section F 108 - 1

Transmission

Section F


108 - 1

PS700 - Mainshaft - Dismantling 1


2 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

1

Remove taper roller bearing using a collet tool and press.

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 pullers, although damage to the bearing cage may be incurred. 217620

3

Remove internal circlip.

4


3

5


4

5

217630

6

Remove taper roller bearing.

7

Position clutch on press and compress piston spring. Remove circlip.

6 7 8

217640

9803/3270

Issue 2

Section F 108 - 2


Section F 108 - 2

PS700 - Mainshaft - Dismantling (cont'd) 8

Remove the spring retaining plate.

9

Remove the spring.

8 9

217651

10

Knock the clutch on a piece of aluminium (or wood) to remove the piston.

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.

217660

11

Piston and hub showing 'O' rings.

Note: Make sure the piston liner is secure. The liner must be a tight fit on the piston.

217670

9803/3270

Issue 2

Section F

Transmission

Section F


108 - 3

108 - 3

PS700 - Mainshaft -Assembly 1

Fit a new 'O' ring onto the shaft.

2

Fit a new ‘O’ ring onto the piston, lubricate both ‘O’ rings and press piston fully into the bore of hub.

A

2

X

* Note: It is recommended that the plastic type piston (shown at A) is replaced with an aluminium type, particularly if water ingress has occurred. Oil baffle 2A will also be required.

1

Ensure the outer seal 2 is correctly seated in its groove. Check that ball valve X is seating properly.

A217670

A217671

3

Fit the piston spring.

4


4

3 2A

A217652 217652

*5

Using a press with cutaway tube Y, compress the piston spring and fit retaining circlip. Also, use the press to fit the taper roller bearing.

5

If a press is not available use spring compressor tool 892/00916 and fit circlip D.

217641

Y

D

9803/3270

Issue 3*

Section F 108 - 4


Section F 108 - 4

PS700 - Mainshaft -Assembly (cont'd) 6

Firstly, fit one steel counter plate followed by one friction plate. Continue fitting alternate plain steel plates and friction plates, finishing with a friction plate.

8

* Note:

When assembling the friction and counter plates ensure they are located to clear the oilways in the clutch body.

* Note:

Later clutch packs are fitted with an additional counter plate before fitting the pressure plate. 7


8


7

6

217630

9


* Note:

Later type shims have teeth on the outside diameter to prevent spinning during operation. Discard old type shims, use the new type shims only.

* Note:

It is recommended that the end float is set to the minimum tolerance. A 6.5 mm (0.25 in) end plate is available. 217680

10

Using a press fit a new taper roller bearing.

11

Fit piston ring seals, see (PTFE) Piston Ring Seal Fitting Procedure.

11 10

217620

9803/3270

Issue 3*

Section F

Transmission

Section F


108 - 5

108 - 5

PS750 - Mainshaft - Dismantling 12 13 14 9 15

10 11

7 2

1

1

8

3

4 6 5

A324750

13 14

2 1

15

12 8

7 5

4

3

9 10 11

9803/3270

A324780 449/11320

Issue 1

Section F


108 - 6

Section F 108 - 6

PS750 - Mainshaft - Dismantling 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 collet tool and press.

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. 3

At the opposite end, loosen the clutch end bearing 3 by tapping the assembly on a piece of wood, then remove end bearing using puller.

4

Remove friction/counter plates retaining circlip 4.

5

Remove pressure end plate 5 and shim 6, if fitted.

6

Remove the clutch friction plates 7 and counter plates 8. Keep them together in sets, DO NOT mix the plates with those from other clutches.

10

Position clutch assembly in press, with a cut away tube compress piston spring then remove circlip 9.

11

Lift off spring retaining plate 10.

12

Remove the spring 11 and oil baffle 12.

13

Knock the clutch on a piece of aluminium (or wood) to remove the piston 13.

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 and discard piston and shaft 'O' rings 14 and 15.

If a press is not available use compressor spring tool A (892/00916) to remove circlip 9. Refit circlip 4 and locate the feet of the tool underneath the circlip. Fit ‘C’ shaped plate over the spring retaining plate, use two bolts B to relieve spring tension and remove circlip 9.

9

B

B A

9

9803/3270

4

Issue 1

Section F 108 - 7


Section F 108 - 7

PS750 - Mainshaft -Assembly Visually inspect the friction and counter plates:

8

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.

Using a dial test indicator as shown, measure the end float of the pressure end plate, which should be 1.9 to 2.5 mm (0.075 to 0.098 in). To adjust the end float, there is a choice between a 6.0mm (0.23in) or 6.5mm (0.25in) pressure end plate 5 with either a shim 6 or extra counter plate 8 between circlip 4 and pressure end plate 5.

9

Smear the clutch end bearings 3 and 2 with JCB HP Grease and press the bearings onto the shaft.

10


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. 1

Fit new 'O' rings 15 and 14, lubricate with oil then press piston 13 fully into the bore of hub.

2

Fit oil baffle 12, piston spring 11, make sure the spring seats in the piston.

3


4

Compress spring and secure with circlip 9.

5

Fit one counter plate 8 followed by one friction plate 7. Continue fitting alternate counter and friction plates, finishing with a friction plate.

6

217680

Fit the pressure end plate 5, do not fit shim 6 at this stage. 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 4.

9803/3270

Issue 1

Section F 109 - 1


Section F 109 - 1

PS700 - Layshaft - Dismantling 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 using a collet tool and press.

1 2

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 pullers to remove it, although damage to the bearing cage may occur. 217700

3

Use a suitable puller to remove both the 4 wheel drive gear and the taper roller bearing.

4

Lift off the full clutch assembly.

3

4

217710

9803/3270

Issue 2

Section F 109 - 2


Section F 109 - 2

PS700 - Layshaft - Dismantling (continued) 5

Remove the spring.

6

Remove and discard the two 'O' rings located on the layshaft.

7

Remove the spring retaining plate.

8

Remove the external circlip.

5

6 7 8

9

Remove the gear and splined hub together with thrust washers and needle roller thrust bearing.

10

Remove the two needle roller bearings.

11

Remove nylon thrust washer.

9

10

11

9803/3270

Issue 2

Section F 109 - 3

Transmission

Section F


109 - 3

PS700 - Layshaft - Dismantling (continued) 12


13

Remove the outer pressure (end) plate.

12

14


13

14

217741

15 * 16

Remove the inner pressure (end) plate. Remove the piston and discard its 'O' ring. Piston A is the plastic type which may be fitted.

15

A

Note: Make sure the piston liner is secure. The liner must be a tight fit on the piston.

16

A217751

9803/3270

Issue 2*

Section F 109 - 4

Transmission

Section F


109 - 4

PS700 - Layshaft - Assembly 1

Fit a new 'O' ring onto the piston, lubricate with oil then press piston fully into bore of the housing.

2 * Note: It is recommended that the plastic type piston (shown at A) is replaced with an aluminium type, particularly if water ingress has occurred. An oil baffle plate will also be required (see step 15). Ensure the outer ‘O’ ring seal is correctly seated in its groove. Check that the ball valve X is seating properly. 2

A X


1

A217751

3

Firstly, fit one friction plate followed by one steel counter plate. Continue fitting alternate friction and plain steel plates, finishing with a friction plate.

*

5

* Note 1: When assembling the friction and counter plates, ensure they are located to clear the oilways in the clutch body.

4

* Note 2: Later clutches are fitted with one 6 mm thick outer pressure plate and one 4 mm thick inner plate. It is recommended that the end float of the clutch plates is set to the minimum tolerance. In order to achieve this, a 6.5 mm thick plate is available if required.

3

4

Fit pressure (end) plate. Make sure that the prongs on the pressure plate DO NOT locate in the large grooves in the hub (the ones with drilled holes).

5


A217742

6

Using a dial test indicator as shown, measure the end float of the pressure (end) plate, which should be 1.90 to 3.20 mm (0.075 to 0.126 in). If necessary, fit shim to correct the end float between the retaining circlip and top pressure (end) plate.

* Note: Later type shims have teeth on the outside diameter to prevent spinning during operation. Discard old type shims, use new type shims ONLY.

217760

9803/3270

Issue 2*

Section F 109 - 5

Transmission

Section F


109 - 5

PS700 - Layshaft - Assembly (cont'd) *7

Fit thin thrust washer A followed by needle roller thrust bearing B and thrust washer C.

* Note: Before fitting the thrust washers and thrust bearing inspect for damage and wear. Renew as required. If the original thrust washer was of the nylon type discard it and fit the thin steel washer A and needle roller thrust bearing B.

C 10 9

B A E

* Note: The thrust washer A is slightly concave and can be fitted either way round but the preferred installation is as shown at E. 8

Fit two needle roller bearings.

9

Fit the gear and splined hub.

* 10

A

Fit thin thrust washer A followed by needle roller thrust bearing B and thrust washer C (see Notes at Step 7).

8

A B 7

11 * 12

13

C

Fit the external circlip. Fit the spring retaining plate. Do not get the oil baffle and the spring retainer mixed up.

13

Fit two new 'O' rings to the layshaft.

12 11

217770

9803/3270

Issue 2*

Section F 109 - 6

Transmission

Section F


109 - 6

PS700 - Layshaft - Assembly (cont'd) 14

Position the clutch assembly on the layshaft splined hub to align the clutch friction/counter plates. Wedge the plates together by inserting two blunt tools (small rounded screwdrivers A) through the bottom holes at the side of the clutch housing, as shown.

14

Remove the wedged clutch assembly.

A

A

217780

* 15

Fit the spring and oil baffle plate.

15

S217790

16

Refit the wedged clutch assembly.

217800

9803/3270

Issue 2*

Section F 109 - 7


Section F 109 - 7

PS700 - Layshaft - Assembly (continued) * 17

18

Position the 4 wheel drive gear on the layshaft spline. Make sure that the gear is fitted the correct way round as shown. On 2 wheel drive machines a spacer is fitted instead of a gear. Position the taper roller bearing on top of the 4 wheel drive gear. Press the taper roller bearing and the 4 wheel drive gear into place using a bench press.

18 17

When the taper roller bearing and the 4 wheel drive gear have been fully installed on the layshaft, remove the two blunt tools (small rounded screwdrivers) used to wedge the clutch plates. Finally, rotate the gear to make sure that the clutch has been correctly installed.

217800

19

Fit piston ring seals, see page F/105-1 for the correct fitting procedure.

19

217700

9803/3270

Issue 2*

Section F

Transmission

Section F


109 - 8

109 - 8

PS750 - Layshaft - Dismantling 25 26 5

3 4

22

23

24

12

16 16 15

1

1

2

14 13 9

10

11

8 7 6 18 19

17

21 20 9803/3270

A324740

Issue 1

Section F

Transmission

Section F


109 - 9

109 - 9

PS750 - Layshaft - Dismantling 1

Carefully remove piston ring seals 1.

9

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.

Remove the gear and splined hub 12 together with thrust washer 13, needle bearing thrust washer 14 and thin thrust washer 15.

10

Remove the two needle roller bearings 16.

2

Remove taper roller bearing 2 using a collet tool and press.

11

Remove thin thrust washer 17 and needle bearing thrust washer 18.

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 to remove it, although damage to the bearing cage may occur which will require a new bearing.

12

Remove the clutch friction/counter plate retaining circlip 19.

13

Remove the outer pressure end plate 20 and shim 21, if fitted.

3

At the opposite end, use a suitable puller to remove both the 4 wheel drive gear 3 (if fitted) and the taper roller bearing 4. Make a note which way round 4 wheel drive gear 3 is fitted for assembly.

14

Remove the clutch friction plates 22 and counter plates 23. Keep them together in sets, DO NOT mix the plates with those from other clutches.

15

Remove the inner pressure end plate 24.

4

Lift off the piston housing 5 complete with clutch pack. 16

Remove the piston 25.

5

Lift off spring retaining plate 6. 17

Remove and discard piston ‘O’ ring 26.

6

Remove the spring 7 and oil baffle 8.

7

Remove and discard the two 'O' rings 9 and 10 located on the layshaft.

Visually inspect the friction and counter plates:

8

Remove circlip 11.

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.

25 24 23 20 26 22 19 3 4

12 5 6 7

8

14 15 17 18

2

1

9 10

9803/3270

11 13

16

A324770 449/11330

Issue 1

Section F 109 - 10


Section F 109 - 10

PS750 - Layshaft - Assembly 1

Fit a new 'O' ring 26 onto the piston 25, lubricate with oil then press piston fully into bore of the housing 5.

2

Fit the inner pressure end plate 24. Make sure the teeth are not aligned with the lubrication slots in the housing.

15

Wedge the plates together by inserting two blunt tools (small rounded screwdrivers A) through the bottom holes at the side of the clutch housing, as shown.

Note: The inner pressure end plate is 4mm (0.157in) thick and should not be confused with the outer pressure end plate which is either 6.0mm (0.23in) or 6.5mm (0.25in) thick. 3

Fit one friction plate 22 followed by one counter plate 23. Continue fitting alternate friction and plain steel plates, finishing with a friction plate.

4

Fit pressure end plate 20. Make sure the teeth are not aligned with the lubrication slots in the housing. Do not fit shim 21 at this stage.

Prior to fitting the clutch assembly, align teeth of clutch plates using a thin rod (screwdriver).

Position the clutch assembly on the layshaft splined hub.

Note: A spring disc is not fitted in this clutch pack. 5

Fit the clutch friction/counter plate retaining circlip 19.

6

Using a dial test indicator as shown, measure the end float of the pressure end plate, which should be 1.90 to 2.5 mm (0.075 to 0.098 in).

A

A

To adjust the end float, there is a choice between a 6.0mm (0.23in) or 6.5mm (0.25in) pressure end plate 20 with either a shim 21 or extra counter plate 23 between circlip 19 and pressure end plate 20. 217780

16

Position the 4 wheel drive gear 3 on the layshaft spline. Make sure that the gear is fitted the correct way round as shown. 2 wheel drive machines have a spacer fitted instead of a gear.

17

Smear the clutch end bearing 4 with JCB HP Grease and press the taper roller bearing and the 4 wheel drive gear 3 into place using a bench press.

217760

When the taper roller bearing and the 4 wheel drive gear have been fully installed on the layshaft, remove the two blunt tools (small rounded screwdrivers) used to wedge the clutch plates. Finally, rotate the gear to make sure that the clutch has been correctly installed.

7

Fit needle roller thrust bearing 18 and thrust washer 17.

8

Fit two needle roller bearings 16.

9

Fit the gear and splined hub 12.

9

Smear the taper roller bearing 2 with JCB HP Grease and press the bearing onto the shaft.

10

Fit thin thrust washer 15 followed by needle roller thrust bearing 14 and thrust washer 13.

10


11

Fit circlip 11.

12


13

Fit two new 'O' rings 9 and 10 to the layshaft.

14

Fit the spring 7 and oil baffle plate 6.

9803/3270

Issue 1

Section F 110 - 1


Section F 110 - 1

Hydraulic 2/4 Wheel Drive Unit Dismantling and Assembly The Powershift 2/4 wheel drive unit dismantling and assembly procedures are the same as for the Syncro Shuttle transmission 2/4 wheel drive units described in this section.

Torque Converter Removal and Replacement The Powershift torque converter removal and replacement procedures are the same as for the Syncro Shuttle transmission, described in this section.

9803/3270

Issue 1

Section F 111 - 1

Transmission

Section F 111 - 1


Torque Converter Stall Test 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. *1

2

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. Apply parking brake and footbrake firmly. If necessary, set the machine against a fixed obstruction.

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

4

Select 2nd speed forward drive and open throttle fully. Record the engine speed from the tachometer. Repeat the test for 3rd speed forward and record the reading. Repeat step 3 except this time select 2nd and 3rd gear reverse drive respectively. Record the readings.

Note: Using 2nd and 3rd gears in forward and reverse drive will ensure that ALL clutches are energised during the test. 5

All recorded readings should be as specified at Torque Converter Stall in Transmission Technical Data.

9803/3270

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 below the Maximum Governed Speed (see Engine Technical Data). If engine speed is correct the torque converter reaction member clutch is slipping. * If the engine speeds are higher than the stated figures in all gears the torque converter safety relief valve may be faulty. * Temporarily bypass the valve (see Pressure and Flow Testing - Bypassing the Converter Relief Valve) and perform the stall tests again. If the engine speeds are as stated the safety relief valve is faulty. Remember to remove the bypass and refit the safety relief valve after this test. If engine speeds are higher than the stated figures check the transmission for clutch slippage or internal leakage. To isolate a suspect clutch, tabulate the recorded readings as shown in the example below: Gear Select

Direction Clutch

Mainshaft or Layshaft Clutch

RPM

2nd 3rd 2nd 3rd

Forward High Forward Low Reverse High Reverse Low

Layshaft Mainshaft Layshaft Mainshaft

2060 1990 1985 1980

In the example shown, we can see that the engine speed is abnormally high when 2nd speed forward drive is selected, indicating a slipping clutch. From the table we can see that the layshaft clutch is working normally (2nd speed reverse drive indicates 1985 rev/min). Therefore it follows that the suspect clutch is the forward high. Assuming all other possible faults have been eliminated (see Powershift fault finding) this clutch would be dismantled for servicing.

Issue 2*

Section F

Transmission

Section F 111 - 2


111 - 2

Testing For Clutch Leakage ! 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.

Example Only Gear Ratio Select Clutch

Mainshaft or Layshaft Clutch

bar

lbf/in2

Trans 2-1

1st 2nd 3rd 4th

Layshaft Layshaft Mainshaft Mainshaft

9.65 8.62 9.65 8.62

140 125 140 125

Solenoid Identification When testing individual clutch pressures (see page F/111-3), it is necessary to isolate the clutch being tested. So for instance, to check the layshaft clutch we could select 1st gear forward - this would energise the layshaft and forward low clutches. Because we only want to check the layshaft clutch pressure and not the forward low clutch pressure, remove the electrical connector to the forward low clutch BEFORE selecting 1st gear. Use the table below to determine which solenoid electrical connectors should be removed when pressure testing individual clutches. Gear Selected

Clutches Engaged (Solenoids Engaged)

1st Forward 2nd Forward 3rd Forward 4th Forward 1st Reverse 2nd Reverse 3rd Reverse 4th Reverse

Forward Low & Layshaft (solenoids 2 & 4 ) Forward High & Layshaft (solenoids 1 & 4 ) Forward Low & Mainshaft (solenoid 2) † Forward High & Mainshaft (solenoid 1) † Reverse Low & Layshaft (solenoids 5 & 4 ) Reverse High & Layshaft (solenoids 6 & 4 ) Reverse Low & Mainshaft (solenoid 5) † Reverse High & Mainshaft (solenoid 6) †

Forward Low Forward High Forward Low Forward High

Readings should not vary between clutches by more than 0.7 bar (10 lbf/in2). In the example shown, we can see that pressure is low when 2nd and 4th gear forward is selected, indicating clutch leakage. From the table we can see that the forward high clutch is used for selection of both 2nd and 4th gear forward. We know from the table that the mainshaft and layshaft clutches are working normally (1st and 3rd gear selection show normal operating pressure). So we can assume that the forward high clutch is leaking. We can now confirm the forward high clutch is leaking by completing an 'Individual Clutch Leakage Test', see next page. Note: Repeat above test using reverse ratios if necessary.

† Note: Solenoid valve 4, when energised, directs pressurised oil to the layshaft clutch. When there is no electrical power at the solenoid, the oil is directed to the mainshaft clutch. Isolating a Suspect Clutch 1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A (mainline pressure test point). 2

A

1

5

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.


Start engine and run at 1000 rev/min, engage 1st gear forward. Record the pressure reading. Repeat the test for all gear ratios in forward drive and record the pressure readings as shown in the example below:

2

4

6

S264530

9803/3270

Issue 1

Section F

Transmission

Section F 111 - 3


111 - 3

Testing For Clutch Leakage (cont’d) Individual Clutch Leakage Test In the following procedures the forward high clutch is tested, therefore in step 2 a pressure gauge is connected to the forward high clutch test point. When testing other suspect clutches connect a gauge to the relevant suspect clutch test point. See page F/111-4 for the position of individual clutch pressure test points. Because the forward high clutch is suspect, a gear must be selected that will use the forward high clutch, in this instance 2nd gear forward. 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A, (mainline pressure test point), see page F/111-4 .

2

Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector G (forward high ratio clutch test point), see page F/111-4 .

3

Remove the layshaft clutch solenoid feed connector 4, this ensures that only the forward high clutch is energised when 2nd gear forward is selected.

Note: See page F/111-2 for identification and position of solenoid feed connectors when testing other suspect clutches. 4

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.


A

G

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/in2). If the difference on the gauges is greater than 0.7 bar (10 lbf/in2) 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/in2) dismantle the forward high 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.

S264710

9803/3270

4 Issue 1

Section F

Transmission

Section F 111 - 4


111 - 4

Pressure and Flow Testing

P

1

2 A314411A

3

4

5 A314411B

S267181

9803/3270

Issue 2

Section F

Transmission

Section F


111 - 5

111 - 5

Pressure and Flow Testing (cont’d) * 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).

TEST POINTS A - Mainline pressure B - Converter inlet/converter relief valve pressure

All gauges etc used in the following pressure/flow tests are shown in Section 1.

C - Converter outlet pressure

! WARNING

E - Layshaft clutch pressure

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

D - Mainshaft clutch pressure F - Pump flow (remove filter and fit adapters) G - Forward high ratio clutch pressure H - Forward low ratio clutch pressure J - Lubrication pressure K - Cooler flow (flowmeter in line from cooler to transmission) L - Reverse high ratio clutch pressure

! WARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

M- Reverse low ratio clutch pressure N - 2/4 wheel drive clutch pressure P - Load Valve

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.

Pump Flow 1

Stop engine, remove transmission filter and filter head adapter. Fit adapter X (892/00920) into the gearbox casing. Fit test adapter Y (892/00301) and secure with adapter Z (892/00302). Connect flowmeter W (892/00229).

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.

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

9803/3270

Mainline Pressure 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) 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.

Issue 2*

Section F


111 - 6

Section F 111 - 6

Pressure and Flow Testing (cont'd) 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).

* 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.

Refer to the illustration on page F/111-4 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) 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.

* Bypassing the Converter Relief Valve During some powershift pressure and oil flow tests it is advisable to temporarily bypass the converter relief valve. If the relief valve opens during the following tests it will cause false results.

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. Refer to the illustration on page F/111-4

Converter Out Pressure/Oil Cooler Flow Rate Converter In Pressure Lubrication Pressure Torque Converter Stall Test IMPORTANT: Before bypassing the torque converter relief valve make sure that the mainline pressure is as shown in Technical Data, see ‘Mainline Pressure’. Make sure that the transmission oil filter is fitted. The torque converter can be damaged when the converter relief valve is bypassed. DO NOT use the load valve or restrict the cooler circuit during this check otherwise the transmission filter may be damaged and leak. Watch the pressure gauge, if high pressures are indicated switch OFF the engine immediately.

1

Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point B.

To temporarily bypass the relief valve (prevent the valve from opening) proceed as follows:

2

Fit a load valve P into the converter out line.

1

Stop the engine and undo the relief valve plug 1.

2

Carefully remove the spring 2.

3

Obtain a suitable spare plug, drill and tap the centre and fit a locking bolt 4.

4

Fit the plug assembly to the relief valve housing and hold the ball 5 on its seat by screwing in bolt 4. Torque tighten the bolt to approximately 30 Nm (22 lbf ft).

! 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/in2) 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.

9803/3270

Before starting testing make sure that the transmission oil temperature is above 50°C. Do not run the engine at more than 2000 rev/min for more than 1 minute. When testing is complete be sure to remove the plug assembly and refit the spring 2 and plug 1.

Issue 2*

Section F 111 - 7

Transmission

Section F


111 - 7

Pressure and Flow Testing (cont'd) Lubrication Pressure

Converter Out Pressure/Oil Cooler Flow Rate

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). Refer to the illustration on page F/111-4

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 and then bypass the relief valve (see Converter Relief (Safety) Valve Pressure and Bypassing the Converter Relief Valve).

1

Refer to the illustration on page F/111-4

2

3

4

Stop engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as shown at J. 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. 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).

1

Note that the flow meter may cause back pressure. If the torque converter relief valve is not bypassed it may open and cause false readings. 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. Remember to remove the torque converter relief valve bypass assembly and refit the relief valve, original spring and plug.

Stop engine and remove pressure gauge.

9803/3270

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge and flowmeter into the converter out line as shown at C and K respectively.

Issue 1

Section F 112 - 1

Transmission

Section F 112 - 1


Flushing the Transmission Oil If the transmission oil has been contaminated with water or incorrect oil types, the transmission must be flushed to effectively remove all the contaminated oil.

F

Flush the transmission as follows: 1

Drain the oil. Remove the suction strainer. Remove bolts B, pull out the strainer A and its gasket D.

2

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

3

Fit the strainer A. Fit a new gasket D. Apply JCB Threadlocker and Sealer to bolts B before fitting and tightening them.

4

Renew the oil filter F.

6

Fill the transmission with fresh JCB Special Transmission Fluid. Check the oil level as detailed in Routine Maintenance.

7

Start the engine and run the machine until the normal operating temperature is reached (between 50 - 100°C).

8

Stall the torque converter for 5 seconds, see Torque Converter Stall Test. DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat.

275150

A B

D A297130

9

Continue running the engine under normal conditions for 5 minutes then repeat step 8. Continue this procedure for 30 minutes, if possible during machine operation.

10

Allow the machine to cool then drain the transmission oil through the suction strainer A.

11

Test the oil for contamination. If the oil is still contaminated, repeat the flushing procedure from step 2. If the oil is clean, refit the suction strainer, fit a new pressure filter and refill the transmission with fresh JCB Special Transmission Fluid. Check the oil level as detailed in Routine Maintenance.

9803/3270

Issue 1

1

Torque Figures and Assembly Notes

1 12

Torque Settings

1 9 12

13

Nm

lbf ft

kgf m

1

56

41

5.7

2

8 - 10

5.9 - 7.4

0.8 - 1.0

3

203

150

20.7

4

102

75

10.4

5

5-8

4 - 5.9

0.6 - 0.8

6

10

7.4

1.0

7

85

63

8.6

8

20 - 24

14.8 - 17.7

2.0 - 2.4

9

25 - 28

18.4 - 20

2.5 - 2.8

10

12

8.8

1.2

12

11

400

296

40

20

Assembly Notes

12

14

21 1

Item 12

Notes Bearings to be lightly oiled before setting and must be rotated whilst being set.

13

Select shims to give input shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

14

Select shims to give mainshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

15

Select shims to give layshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

12 12 11

15

.....continued

16

A324810 449/00002

119 - 1

Issue 1

12

Section F

9

Transmission

12

19

Item


18

12

Section F

Sheet 1 of 3

119 - 1

9803/3270

PS750 Section Views and Torque Figures

Assembly Notes (continued)

8

16

Select shims to give 4WD output shaft to give 4WD output shaft end play of 0.03 mm (0.001 in) maximum.

17

Select shims to give reverser shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

18


19

Tighten stake nut to a torque of 300 Nm (221 lbf ft: 30.6 kgf m). Stake nut sleeve to be split axially using square ended staking tool.

20

Assemble with tapped extraction holes facing out.

21

The transmission should be rebuilt with a solid spacer, which is the preferred option. However in the absence of the special tools required or of a solid spacer, a collapsible spacer may be fitted.

9

1

4 7 5 9

10

1

9

1

12 4

1

1

1

9

17 1

6

Fit the solid spacer to give a combined seal and bearing rolling torque not exceeding a maximum of 2.0 Nm (1.5lbf ft) when fully torque tightened.

Section F

.....continued

119 - 2

Issue 1

A324820 449/00002

Transmission

Notes


Item

Section F

119 - 2

9803/3270

Sheet 2 of 3


Assembly Notes (continued) Item 22

4 4 9 1

Notes Measure end float of pressure plate. Free movement on plates to be : Mainshaft clutch - 1.9 to 2.5 mm (0.075 to 0.098 in). Input/Reverser - 1.9 to 2.5 mm (0.075 to 0.098 in). Layshaft clutch - 1.9 to 3.2 mm (0.075 to 0.098 in).

1

9 1

1

9

23

Pack bearings with grease before assembly.

24

The illustration on sheet 1 shows a 2/4 wheel drive clutch pack. For permanent 2 or 4 wheel drive see Transmission contents if applicable.

Transmission

9


To adjust the end float, there is a choice between a 6.0mm (0.23in) or 6.5mm (0.25in) pressure end plate with either a shim or extra counter plate between circlip and pressure end plate.

1

Section F

Sheet 3 of 3

119 - 3

9803/3270


3

Section F

119 - 3

Issue 1

A324830 449/00002

Section F

Transmission

Section F

Powershift (With Reverser Shaft Sealing Plug & PS750)

120 - 1

120 - 1

36 9 7 11

13

12

10

8

56 23 42

22

24

21

43 45

46

47

25 20 33

34

18

55

19

35 50

30

32

17

51

31

15

40

5

16

29

14

6 58 38 P

57

54 53

37

39

57

41 57 49

38

V 27

57 Q 38

49

38

57 T

52 57

4

57 48 26

44 1 3

49 2

9803/3270

28

A311910

Issue 2

Section F 120 - 2

Transmission Powershift (With Reverser Shaft Sealing Plug & PS750)

Section F 120 - 2

List of Components The illustration shows all the components which are referred to in the dismantling/assembly procedures. Depending on the transmission, some of the items shown may not be fitted (e.g. 5, 7). 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Bolt Oil Strainer Gasket Drain Plug Oil Filter (if fitted) Oil Pressure Switch Speed Sensor (if fitted) Sealing Caps Screw Solenoid Control Valve (Reverse High/Low) Solenoid Control Valve (Mainshaft/Layshaft) Solenoid Control Valve (Forward High/Low) ‘O’ Rings Transmission Pump Mounting Screws Transmission Pump Assembly Pump Sealing Ring Pump Housing Oil Seal Nut 4WD Solenoid Control Valve 4WD Valve Spool Plug Pressure Maintenance Valve Bolt Solenoid Adapter Block 4WD Oil Feed Pipe (if fitted) Cover Bolts 4WD Clutch Assembly Gasket Torque Converter Relief Valve Cover Bolts Layshaft End Cap Gasket Shim(s) ‘O’ Ring Casing Joint Bolts Transmission Rear Case (Output End) ‘O’ Ring (3) Shim(s) Flywheel Housing Mounting Bolts Flywheel Housing Dowels (if fitted) Brake Disc Output Shaft Nut & Washer Output Shaft Oil Seal Outer Taper Roller Bearing Spacer Inner Taper Roller Bearing Piston Ring Seals Reverser Shaft Sealing Plug Sealing Washer Transmission Front Case (Input End) Spacer ‘O’ Rings Adapter Block Gasket Brake Mounting Plate Taper Roller Bearing Spacer

9803/3270

P Q T V

Reverser Clutch Assembly Mainshaft Clutch Assembly Layshaft Clutch Assembly Input Clutch Assembly

Note: Production transmissions have the shims fitted in the front case; however, when servicing the Powershift, it is permissible to fit shims 38 in the rear case.

Issue 2

Section F

Transmission

Section F


120 - 3

120 - 3

Dismantling 1

Place a container of suitable size beneath the strainer to catch the oil. Remove screws 1.

2

Withdraw strainer 2.

3

Remove and discard gasket 3.

6


4

Remove drain plug 4, complete with its washer.

5

Remove and discard the oil filter (if fitted) 5.

5

3 4

1

Note: Some machines have a remote mounted oil filter. 6

Remove the pressure switch 6.

2 7

S217452

Remove the speed sensor 7 (if fitted), its spacer and ‘O’ ring. Retain the spacer for assembly.

7

A312080

8

9

Remove the plastic water seals 8 to reveal capscrews 9 then unscrew cap screws 9 and remove the reverse high/low clutch solenoid valve 10.

10

13

11

12

Similarly remove the mainshaft/ layshaft clutch solenoid valve 11. A310580

10 Similarly remove the forward high/low clutch solenoid valve 12. When the solenoid valves are removed, discard the four surface mounted ‘O’ rings 13 from the valve body.

9

Refer to Solenoid Valve for the solenoid valve dismantling and assembly procedure, if further work is necessary on any of the solenoid valves.

8

9803/3270

Issue 2

Section F 120 - 4

Transmission

Section F


120 - 4

Dismantling (cont’d) 11 Unscrew bolts 14 and withdraw the transmission pump assembly 15. 12 Remove and discard the pump sealing ring 16.

16 14

13 Separate pump components. 14 Remove and discard oil seal 17 from pump housing.

15

17 Steps 15 and 16 apply only to 4WD transmissions.

19 21

15 Unscrew nut 18 on the 4WD solenoid 19 and remove the solenoid.

18

22

16 Remove the 4WD solenoid valve spool 20. 17 Unscrew plug 21 and withdraw pressure maintenance valve spool and spring 22.

20

18 Unscrew the bolts 23 and remove the solenoid adapter block 24. 19 Remove and discard the solenoid adapter block gasket.

25

24

9803/3270

23

Issue 2

Section F 120 - 5

Transmission

Section F


120 - 5

Dismantling (cont’d) Steps 20 to 22 apply only to 4WD transmissions.

C

20 Remove the 4WD assembly oil feed pipe 25. Note that if the 4WD oil feed pipe is of the bundy type it should be replaced by the later version, with an external flare design, complete with new adapters C and D. 21 If the transmission is fitted with an optional 4WD pipe guard, remove the guard by unscrewing the two mounting bolts E.

D

25

E S267920

22 Unscrew bolts 26 and if fitted, remove the 4WD unit with its clutch assembly 27. Discard sealing gasket 28. See Hydraulic 2/4 WD unit - Spring ON/Pressure OFF or Pressure ON/Spring OFF for dismantling and assembly procedures.

26 27

Note: If the flywheel housing flange is the SAE (circular) type, it will be necessary to remove the SAE flange before the 4WD clutch unit can be removed - refit the SAE flange after removing the 4WD clutch unit. Also, if the 4 wheel drive unit is to be dismantled, then hold the flange with tool 892/00812 and loosen the 4 wheel drive flange retaining nut/bolt prior to removing the complete 4 wheel drive assembly.

28

9803/3270

Issue 2

Section F 120 - 6

Transmission

Section F


120 - 6

Dismantling (cont’d) 23 Position transmission vertically, standing on face of flywheel housing as shown.

31 30

CAUTION: The Powershift transmission weighs approximately 278 kg (613 lb) when dry. Suitable equipment must be used to manoeuvre the transmission into a vertical position. 24 Remove the torque converter relief valve ball, tapered spring and sealing washer 29.

32 33 34

25 Remove bolts 30 and remove the layshaft end cap 31. Discard the sealing gasket 32. 26 Remove the layshaft shim 33 and ‘O’ ring 34.

36

27 Unscrew bolts 35 and separate the rear (output) end casing 36. Sealant will hold the casings together, carefully tap the casing while gently levering apart at X, (shown at next step). Note: Make sure that internal components remain seated in the front casing. If necessary, rotate the brake disc back and forth slightly to dislodge the internal components.

35 29 S217191

28 Remove and discard the three ‘O’ rings 37 (fitted next to the input and reverser clutch assemblies).

T

29 Tilt and lift out the layshaft assembly T.

37 Note: For reference, the clutch assemblies are identified as follows: P = Reverser Clutch T = Layshaft

X

V

Q

Q = Mainshaft V = Input Clutch

30 This step requires the help of an assistant. Have the assistant SLIGHTLY lift and tilt both the mainshaft and input clutch as shown; then tilt and lift out the reverser clutch P. 31 Slightly lift the input clutch and at the same time tilt and lift out the mainshaft Q. 32 Lift out the input clutch V.

P X

S217210

* Note: Retrieve shims 38 from casing for re-use, see complete assembly illustration at the beginning of the dismantle procedure. Dismantling and assembly procedures for the shaft and clutch assemblies are given elsewhere in this manual. * The procedure for PS700 and PS750 differ, make sure you use the correct procedure.

9803/3270

Issue 3*

Section F 120 - 7

Transmission

Section F


120 - 7

Dismantling (cont’d) 41

33 Unscrew bolts 39 and remove the flywheel housing 40. Note: Dowels 41 locate the flywheel housing on the transmission. Using a soft faced hammer, tap the housing to release it from the dowels.

40

39

34 Mark the position of the brake disc 42 on the splined output shaft 44. Whilst holding the brake disc with tool 992/04800, unscrew output shaft nut 43. Support output shaft 44 from beneath and lift off the brake disc. Remove the output shaft assembly.

43

35 Prise out oil seal 45 and discard.

42

36 Remove outer taper roller bearing 46. 37 Remove spacer 47 and retain for assembly. Note: If spacer 47 is the collapsible type X, discard it.

45 46

38 Using a suitable puller, withdraw inner bearing 48. 39 Finally, after repair and renewal of parts, make sure casings and parts have been thoroughly cleaned using suitable solvents before starting the assembly procedures. Ensure the suction strainer is thoroughly cleaned and dried ready for assembly.

* 40

A

If required, the new type parking brake bracket A can be removed at this stage, before removing mark the position of the bracket relative to the casing.

Y 47 44 48

X

A217203

9803/3270

Issue 3*

Section F 121 - 1

Transmission

Section F


121 - 1

Assembly 1

Before starting the assembly of the powershift transmission make sure that all casings and components, including the suction strainer, have been thoroughly cleaned with a suitable solvent. When assembling, smear bearings with JCB HP Grease. Renew all ‘O’ rings, seals and gaskets. Finally, please remember that dirt in the transmission system will cause damage to the powershift and its associated parts, in particular the transmission pump.

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. 2

Using a new gasket, install suction strainer. Apply JCB Threadlocker and Sealer to bolts 1 and tighten to 10 Nm (7 lbf ft).

1 S217230

45

Note: If the new type parking brake mounting bracket A has been removed it must be fitted at this stage in the position as marked during dismantling, see page G/22-10 for torque figures. When building a transmission with a solid spacer a 15mm (0.5in) diameter hole will have to be drilled at B to enable the fitting of the tool for checking the end float. 3

46 A

Lightly oil output shaft inner bearing 48 and cup and fit to output shaft 44.

The transmission should be rebuilt with a solid spacer 47, which is the preferred option. However, in the absence of the special tools required or of a solid spacer, a collapsible spacer may be fitted as described under Collapsible Spacer - Assembly.

36

See Service Tools, Section 1 for Setting Tool Kit, part number and details of spacers. a

Fit the solid spacer 47 (13.70 mm thick, part number 921/52620) over output shaft 44 and assemble into casing 36.

47

b Lightly oil output shaft outer bearing 46 and cup and fit to output shaft 44, do not fit oil seal 45 at this stage.

13.70 82mm 75mm

47 44 48

B A217204

9803/3270

Issue 5

Section F 121 - 2

Transmission

Section F


121 - 2


Fit special tool sleeve A, which temporarily replaces the disc brake, and secure with special tool nut B, torque tighten to approx. 50 Nm (36.9 lbf ft).

C

Note: Check for end float while tightening nut B, if there is no end float check the following:

B

The bearing cups are pushed fully into the casing.

D A

The correct bearings are fitted. The solid spacer 47 is 13.70 mm thick. Fit special tool support pillar C so that the fork end engages in special tool nut B, tighten bolt D.

S265900

5

a

Fit dial test indicator (DTI) E.

E


To select the right size spacer 47, subtract the end float obtained at step b from the solid spacer J (13.70 mm). Also subtract 0.120 mm to allow for bearing tolerance and pre-load. If there is no spacer of this size, fit the next smallest spacer.

Example Service spacer Subtract end float = Subtract tolerance & preload Result

13.70 0.41 13.29 0.12 13.17

Use next smallest spacer i.e.

13.15

F S265910

If the ‘Result’ measurement is outside the spacer kit range check the assembly of the bearings. If the bearings are assembled correctly use a collapsible spacer, see Collapsible Spacer - Assembly.

B

d Remove nut B, sleeve A, outer bearing and fit correct size spacer 47. Take care to avoid damaging the outer bearing.

f

Fit sleeve A and initially tighten nut B to approx. 50 Nm (37 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.

A311530

e

A J

B A

A311530

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. S265900

9803/3270

Issue 2

Section F 121 - 3

Transmission

Section F


121 - 3


a

Remove nut B and sleeve A. Fit new oil seal 45 (grease between seal lips before fitting). Assemble brake disc/flange 42 (the disc/flange may be a tight fit) using the alignment marks made during dismantling.

43

42

Note: Do not excessively hammer the disc during assembly or damage to the shaft bearings could occur. If necessary, press fit the parts. Fully support the shaft during assembly.

45

b Fit NEW retaining nut and washer 43 and progressively torque tighten to 300 Nm (221 lbf ft). Provided the correct size spacer has been selected the combined seal and bearing rolling torque should not exceed a maximum of 2.0 Nm (1.5 lbf ft) when 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. c 7

A273410

Finally stake nut 43 into the slot in the shaft.

Position the transmission vertically on wooden blocks to give clearance to the input shaft. Smear pump end bearings with JCB HP Grease, then carefully lower input V and reverser P clutches into casing.

49

V

Note: To prevent damaging input shaft piston ring seals 49, it is permissible to remove the seals prior to assembling case halves. However, this is applicable only whilst measuring shaft end float. REFIT THE SEALS BEFORE FINAL ASSEMBLY.

49

P

S311280

8

Assemble the two halves of the casing using 4 equally spaced bolts 35 and tighten bolts to 56 Nm (42 lbf ft).

Note: Assembling the case halves at this stage is a temporary arrangement to enable measurement of the input and reverser shaft end float. DO NOT apply JCB Threadlocker and Sealer to the bolts at this stage or bond mating faces.

35

A217261

9803/3270

Issue 2

Section F 121 - 4

Transmission

Section F


121 - 4


Measure the end float of the input shaft using the end float checking kit. a

11 3

If it has not already been done, insert an M10 bolt into the recessed hole in the base plate 2 and mount pillar 12. Tighten the bolt ensuring that the slot in the pillar faces the input shaft. Mount the base plate onto the transmission casing.

12 13

b Select adapter tool 13 and screw into the tapped hole in the input shaft. Locate yoke 3 and wrench 11 into the adapter tool 13 and pillar 12. Set the wrench to 35 Nm (26 lbf ft). c

A

2

B A311450

Using a magnetic block, mount the Dial Test Indicator (DTI) A with the probe on the head of the adapter 13 and adjust to read zero.

d Whilst rotating the input shaft back and forth using the splined wrench B, (which can be manufactured from an old torque converter hub), to seat the bearings, lift and depress wrench 11 and note the reading on the DTI. e

Remove wrench 11 and base plate 2 from the transmission casing.

f

Calculate the required thickness of shims to give the correct end float which should be 0.03 - 0.08 mm (0.001 - 0.003 in).

10 If the end float checking kit is not available use the following procedure: a

Protect the input shaft V with a metal sleeve and clamp vice grips into position. Set up a DTI as shown at C and using the grips as a lever, rotate the shaft to seat the bearings fully whilst measuring the end float. Remove the DTI and vice grips from the transmission.

C

V

b Calculate the required thickness of shims to give the correct end float which should be 0.03 - 0.08 mm (0.001 - 0.003 in). A311260

9803/3270

Issue 2

Section F 121 - 5

Transmission

Section F


121 - 5

Assembly (cont’d)

a

7

51

11 Measure the end float of the reverser shaft using the end float checking kit.

A

50

Remove plug 50 and sealing washer 51 from the transmission casing. Discard the washer 51.

3 7

b Select adapter 7 from kit and screw into the tapped hole in the reverser shaft. c

Mount base plate 2 onto the transmission casing and locate yoke 3 and wrench 11 into the adapter 7. Set the wrench to 35 Nm (26 lbf ft).

11

V A311470

d Using a magnetic block, mount the Dial Test Indicator (DTI) A with the probe on the head of the adapter 7 and adjust to read zero. e

Whilst rotating the reverser shaft back and forth using the splined wrench on the input shaft to seat the bearings, lift and depress wrench 11 and note the reading on the DTI.

f

Remove the wrench 11 and adapter 7 from the reverser shaft assembly.

g Calculate the required thickness of shims to give the correct end float which should be 0.03 - 0.08 mm (0.001 - 0.003 in).

12 If the end float checking kit is not available, use the following procedure: a

Carry out item a of step 10. Screw a suitable M10 bolt A into the tapped hole in the end of the reverser clutch shaft. Set up a Dial Test Indicator (DTI) as shown at C and rotate the shaft to seat the bearings fully using the vice grips on the input shaft. With a lever under the bolt head, move the shaft back and forth and measure the end float. (The end float should be set as near as possible to the minimum tolerance.) Remove the DTI and vice grips from the transmission. Retain the bolt in the reverser shaft.

b Calculate the required thickness of shims to give the correct end float which should be 0.03 - 0.08 mm (0.001 - 0.003 in).

9803/3270

C

A

A311270

Issue 2

Section F 121 - 6

Transmission

Section F


121 - 6

Assembly (cont’d) 13 Separate the two halves of the casing and add or subtract shims 38 fitted beneath the outer races in the rear (output) case 36 to correct input and reverser clutch shaft end float. Repeat step 11 or 12 to re-check the end float. Note: Production transmissions have the shims fitted in the front case; however, when servicing the Powershift, it is permissible to fit shims 38 in the rear case as shown.

38

36 38

When correct end float has been achieved, remove the input and reverser clutch shafts and refit piston ring seals 49 removed in step 7, (see page F/105-1). Remove the bolt A (see step 12) from the reverser shaft.

S217280

Note: Do not re-fit the input and reverser clutch shafts at this stage. They must be fitted together with the other shafts in the transmission - see steps 14 to 16.

14 Fit the input clutch V and the mainshaft Q simultaneously into the front case as shown. Before fitting make sure that all piston ring seals have been renewed and are lightly greased and are fully seated in their grooves, see Piston Ring Seal - Fitting Procedure. Also ensure that both the input clutch and mainshaft taper roller bearings have been smeared with JCB HP Grease. 15 This step requires the help of an assistant. Have the assistant SLIGHTLY raise and tilt the input clutch and mainshaft, whilst the assistant is holding the two units, fit the reverser clutch P.

T V

Q

P

16 Smear the layshaft taper roller bearing with JCB HP Grease and fit the layshaft assembly T into the front case. The arrangement of the clutch assemblies should now be as shown opposite. Make sure that all bearings are fully seated, and that the relevant gears have meshed correctly.

S217290

17 Using two small rods (or screwdrivers) A, align all the friction/counter plates of the mainshaft clutch. 18 Fit three new ‘O’ rings 37 in the front case 52. Smear the ‘O’ rings with grease to hold in position.

37

A

Note: Do not apply an excessive amount of JCB Multigasket around the ‘O’ rings, too much can dislodge the ‘O’ rings. 19 Apply JCB Multi-gasket to the front case mating face. Prior to fitting the rear (output) case, ensure that all bearings have been smeared with JCB HP Grease. Ensure that all piston ring seals are fully seated and have been smeared with grease.

9803/3270

52 S217300

Issue 2

Section F 121 - 7

Transmission

Section F


121 - 7

Assembly (cont’d) 20 Make sure all the friction/counter plates in the mainshaft clutch are aligned (see step 17). Carefully lower the rear (output) case into position, taking care to align output gear splines with the mainshaft clutch friction/counter plates. Gently rotate the disk back and forth to enter the the plates, if the casing does not drop down onto the dowels do not use the bolts or force as the plates will be damaged. Apply JCB Threadlocker and Sealer to bolts and torque tighten to 56 Nm (42 lbf ft). To assist in fitting the rear case and keep the mainshaft plates aligned, fit an airline adapter tool with tap, (see Section 1) as shown at Y. Fit a suitable airline and apply 5.5 bar, (80lbf/in2, 5.6 kgf cm2), use tap to regulate the airflow to keep the clutch pack locked up.

31

30

32

33

21 Using a new gasket 32, temporarily fit the layshaft end cap 31 and shims 33, torque tighten retaining bolts 30 to 56 Nm (42 lbf ft).

Y

Note: Fitting the layshaft end cap at this stage is a temporary arrangement to enable measurement of the layshaft end float. Do not apply JCB Threadlocker and Sealer to retaining bolts at this stage. Note: Take care not to damage the gasket as it must be used for final assembly.

A217341

316530

22 Measure the end float of the layshaft using the end float checking kit. a

Locate the transmission on a bench with the input side uppermost so the disc can be turned.

b Secure the base plate 2 on the face of the casing using the existing tapped holes for the mounting bolts and tighten to 56 Nm (42 lbf ft). Fit a splined wrench over the input shaft end B. c

A

B

3

11

Select adapter 8 from the kit and screw into the tapped hole in the layshaft.

5 d Locate the yoke 3 and wrench 11 into the adapter 8 and pillar 5. Set the wrench to 35 Nm (26 lbf ft). e

f


8 2 A310530

Whilst rotating the layshaft back and forth using the disc on the output shaft to seat the bearings, lift and depress the wrench 11 and note the readings on the DTI.

g Remove the wrench 11 and adapter 8 from the layshaft assembly. h Calculate the required thickness of shims to give the correct end float which should be 0.03 to 0.08 mm (0.001 to 0.003 in). (The end float should be set as near as possible to the minimum tolerance.)

9803/3270

Issue 2

Section F 121 - 8

Transmission

Section F


121 - 8

Assembly (cont’d) 23 If the end float checking kit is not available use the following procedure: Set up a DTI on a suitable M10 bolt and measure layshaft end float, which should be 0.03 to 0.08 mm (0.001 to 0.003 in). Rotate the shaft whilst measuring to seat bearings fully. When measuring the end float, move the layshaft by hand, gaining access through the 4WD housing or rotate the output disc on 2WD.

X

Note: Access to the layshaft end face is gained through 4WD bolt hole X, as shown. Calculate the required thickness of shims to give the correct end float. (The end float should be set as near as possible to the minimum tolerance.) When calculating the shims required take into account the gasket thickness.

S217330

24 Remove the layshaft end cap 31. Smear the layshaft outer bearing with JCB HP Grease and add or subtract shims 33 to give correct end float (fit shims between outer race of bearing and layshaft end cap).

31 30

25 Fit a new ‘O’ ring 34 in the end cap 31. Smear the ‘O’ ring with grease to hold in position.

32

26 Refit the layshaft end cap 31 with new gasket 32. Apply JCB Threadlocker and Sealer to bolts 30 and torque tighten to 56 Nm (42 lbf ft).

33 34

A217341

9803/3270

Issue 2

Section F 121 - 9

Transmission

Section F


121 - 9

Assembly (cont’d) 27 Measure the end float of the mainshaft using the end float checking kit. a

54

Remove the mainshaft end spacer 53. Remove and discard the two ‘O’ rings 54. DO NOT fit ‘O’ rings at this stage (see note), refit the spacer. End spacers have extraction holes to assist removal. Fit the spacer with the extraction holes facing towards you.

Note: This is a preparatory step for setting the mainshaft end float. At a later stage it will be necessary to remove the end spacer so that shims can be fitted to set the end float. If the ‘O’ rings are left on at this stage, the spacer will be difficult to remove. New ‘O’ rings are fitted once the correct mainshaft end float has been set.

53 S217241

b Install tool 892/00295 B over the mainshaft end bearing and spacer. Tighten bolts to 56 Nm (42 lbf ft). c

B

Screw adapter 4 into the tapped hole in the mainshaft.

d Mount base plate 2 onto the transmission and locate yoke 3 and wrench 11 into the adapter 4 and pillar 6. Set the wrench to 35 Nm. e


f

Whilst rotating the mainshaft back and forth to seat the bearings, lift and depress wrench 11 and note the reading on the DTI.

S217351

Note: To rotate the mainshaft gain access through the 4WD cover. On 2WD transmissions use an airline and adaptor tool, see page F/121-7 step 20.

6 4

g Remove the wrench 11, adapter 4 and float setting tool from the mainshaft assembly. h Add or subtract shims to correct the end float. (The end float should be set as near as possible to the minimum tolerance.) The shims must only be fitted between the bearing outer race and spacer. When the correct end float has been established - REFIT THE SPACER 53 WITH NEW ‘O’ RINGS 54.

A 3 11

2

A311460

j

Repeat steps 9A - 9E to recheck the input shaft end float.

k

Repeat steps 11A - 11F to recheck the reverse shaft end float.

l

Remove bolt A, (see step 12) from the reverser shaft and fit plug 50 with new seal 51.

9803/3270

Issue 2

Section F 121 - 10

Transmission

Section F


121 - 10

Assembly (cont’d) 28 If the end float checking kit is not available, use the following procedure: a

Carry out items a and b of step 27.

b Screw a suitable bolt into the tapped hole in the end of the mainshaft and using a suitable lever under the bolt, move the mainshaft back and forth when setting the end float. c

Set up a DTI as shown and measure mainshaft end float which should be 0.03 to 0.08 mm (0.001 to 0.003 in). Rotate mainshaft whilst measuring in order to seat bearings fully.

Note: To rotate the mainshaft gain access through the 4WD cover. On 2WD transmissions use an airline and adaptor tool, see page F/121-7 step 20. d Add or subtract shims 38 to correct the end float. (The end float should be set as near as possible to the minimum tolerance.) The shims must only be fitted between the bearing outer race and spacer. When the correct end float has been established REFIT THE SPACER 53 WITH NEW ‘O’ RINGS 54.

S311430

54 53 38

29 Using a new gasket 28, install the 4WD unit. Apply JCB Threadlocker and Sealer to bolts 26 and tighten to 56 Nm (42 lbf ft). Note: On 2WD machines, the 4WD cover may be sealed with a either a blanking plate or a 2WD type casing.

28

Note: Depending on the type of machine, the yoke is secured by either a nut or flanged bolt. For end float setting and dismantle/assembly procedure, see Hydraulic 2/4 Wheel Drive Unit.

26 S311550

9803/3270

Issue 2

Section F 121 - 11

Transmission

Section F


121 - 11

Assembly (cont’d) 30 If the pump flow/pressure was below normal, coat the machined face of the pump with engineers’ blue and insert into the pump housing. Fit pump and tighten bolts 14 evenly to 25Nm (18.5 lbf ft, 2.5kgf m) remove carfully. Check the machined faces for contact. Remove high spots as necessary until full face contact is made. Thoroughly clean all surfaces with suitable solvent and dry before installing. Make sure all bearings have been lubricated with JCB HP Grease. Apply JCB Multi-gasket to mating face of flywheel housing. Fit the flywheel housing, locating it on dowels 41. Apply JCB Threadlocker and Sealer to bolts 39 and torque tighten to 56 Nm (42 lbf ft).

41

39 16

14

A 17

40

31 Assemble pump (if dismantled). Install pump taking care to align mounting holes. Apply JCB Threadlocker and Sealer to bolts 14 and using new sealing washers, tighten to 25 Nm (18 lbf ft). Use a new pump housing seal 16. Ensure a sufficient quantity of clean new oil is added to the pump for initial start-up lubrication of the gears. Note: There are two types of pump housing seal 16 depending on the pump type fitted. Ensure the correct seal is fitted: Existing seal outside diameter = 69.95 mm (2.754 in). Alternative seal outside diameter = 68.22 mm (2.685 in). Note: After fitting the transmission pump, rotate gear A to ensure it has clearance and turns freely.

32 Fit torque converter relief valve ball and tapered spring 29. Make sure that the larger diameter of the tapered spring is located securely over the spigot on the plug. Use a new sealing washer, then fit and tighten plug.

29

S217440

9803/3270

Issue 3

Section F 121 - 12

Transmission

Section F


121 - 12

Assembly (cont’d) 33 Before fitting solenoid adapter block to a new casing, ensure that the M8 oilway blanking plug A is fitted. Apply JCB Threadlocker and Sealer to the thread and screw into position 1 mm (0.04 in) below the valve block face.

21

19 18

36 22

Using a new gasket 55 (see main illustration at the beginning of Dismantling), fit the solenoid adapter block 24 to the casing 36. Apply JCB Threadlocker and Sealer to bolts and tighten to 25 - 28 Nm (18 - 20 lbf ft).

20

34 Assemble pressure maintenance valve spool and spring 22 into adapter block 24. Fit and tighten plug 21. Do not over-tighten as damage to the aluminium housing could result. Note: Fit new spring and plug combinations giving the correct operating pressures as follows: High Pressure Backhoe Loaders from Oct 1996 fitted with high pressure filter.

28.4 62.7

ITL01720 S316270

24

S217171

Low and Standard Pressure Backhoe Loaders to Oct 16.0 1996 and 2CX, Loadall, RTFL.

49.9

A311520 A311520

Low Pressure

A

406, 407, 408, 409

A264231

122mm

DO NOT mix springs and plugs. The measurements are given in mm. 65mm

A311540

Note: Some plugs and springs have been superseded, which differ from the above measurements, measure and if not as above fit new spring and plug. On 4WD transmissions only 35 Renew ‘O’ rings and fit the 4WD valve spool 20. 36 Install the 4WD solenoid valve body 19. Apply JCB Threadlocker and Sealer to the spool thread, fit the retaining nut and torque to 7 Nm (5 lbf ft). CAUTION: Overtightening the retaining nut will cause valve failure. Note: Because of porting differences the Powershift and Syncro Shuttle 4WD spools are not interchangeable.

9803/3270

Issue 2

Section F 121 - 13

Transmission

Section F


121 - 13

Assembly (cont’d)

B

37 Fit the 4WD assembly oil feed pipe 25 (support bracket not shown).

C

The older type pipe is now superseded by an external flare design B with new adapters C and D. The old pipe can be replaced with the new type providing the new adapters C and D are used.

D

To install the new design of pipe: a

Remove and discard the old type pipe and adapters.

b

Fit adapters C and D with appropriate bonded washers (see Service Tools - Section 1).

c

Fit the new design pipe, making sure the pipe is not twisted or strained before tightening the nuts to 56 Nm (42 lbf ft).

25

E

Note: A 4WD pipe guard A is available as a service fit option. The 4WD guard is installed using two bolts E as shown. Use JCB Threadlocker and Sealer on the bolts and torque tighten to 56 Nm (42 lbf ft).

38 Renew the surface mounted ‘O’ ring seals 13 in the valve body.

A

S267920

12

13

39 Mount the forward high/low clutch solenoid valve 12 onto adapter block. Fit cap screws 9 and tighten to 5 Nm (4 lbf ft).

11

10 8

A310580

40 Repeat for the mainshaft/layshaft clutch solenoid valve 11 which may be a single coil or double coil as shown. 41 Repeat for the reverse high/low clutch solenoid valve 10. Note: The mounting holes will only align when the solenoid valve has been positioned correctly on the adapter block 24. 42 After assembly, ensure that the plastic caps 8, are inserted into the mounting screw counter-bores to prevent the ingress of water and dirt which could prevent removal at a later date.

9803/3270

9

24

Issue 2

Section F

Transmission

Section F


121 - 14

121 - 14

Assembly (cont’d) 43 Smear seal of new filter 5 with transmission oil. Screw the filter on until it just contacts the filter head. Turn the filter at least another 3/4 of a turn.

6

44 Fit the drain plug 4 with a new sealing washer - torque tighten to 203 Nm (150 lbf ft). 45 Refit the pressure switch 6 with a new sealing washer. Torque tighten the switch to 28 Nm (21 lbf ft).

5

46 Test points have been introduced that can be left in position after testing. If leaving test points in place use Threadlocker and Sealer when fitting. Remove blanking plugs as required and fit test points, see section 1.

4

S217452

47 Fit the electronic speed sensor or blanking plug as applicable. Note: Some machines are fitted with a spacer A. The thickness of spacer A is dependant on the number of teeth on the transfer gear. If a new spacer is fitted make sure it is the correct thickness. Fitting incorrectly will cause the speed sensor to be damaged or inoperable.

B C

A

Spacers must be fitted as follows: Transfer Gear Teeth 45T 46T 47T

Transmission Ratio Standard Low Ratio Extra Low Ratio

Spacer A No spacer fitted 3.6 mm thick spacer 5.1 mm thick spacer

48 Fit new ‘O’ ring. 49 Locate speed sensor together with the correct spacer A (when applicable). Fit retaining screw. Note: Some machines have no speed sensor and incorporate a blanking plug B. If the plug has been removed, fit a new ‘O’ ring C before replacing the plug.

A297050

9803/3270

Issue 2

Brakes

Section G

Section G

i

i

Contents

Page No.

Technical Data

1-1

Descriptions Compensating Master Cylinder - Pedals Locked - Normal Operation - Pedals Locked - Compensating Operation - Pedals Unlocked - Normal Operation

2-1 2-1 2-1

Fault Finding Brake System Brake Piston Seal Leakage Test

5-1 5-4

Brake System - Bleeding

11 - 1

* Parking Brake Caliper

Testing the Parking Brake Parking Brake Ajustment Dismantling and Assembly Type 1 Removal and Replacement Type 2 Dismantling and Assembly Type 2 Torque Figures

9803/3270

22 - 1 22 - 2 22 - 4 22 - 5 22 - 7 22 - 10

Service Brakes Dismantling and Assembly

23 - 1

Master Cylinder and Servo Unit Removal and Replacement Dismantling and Assembly

30 - 1 31 - 1

Issue 2*

Section G

Brakes Technical Data

1-1

Service Brake Type

Section G 1-1

JCB Oil-Immersed Multi-Plate Disc

Actuation

Hydraulic - vacuum servo assisted for machines powered by model AB turbocharged engine

Location

Rear Axle Centre Casing (2 brake packs)

Friction Plates (5 per brake pack) Outside Diameter * Inside Diameter * Nominal Facing Area per Plate Hydraulic Piston Diameter

220 mm (7.992 in) 160 mm (6.299 in) 18603 mm2 (28.8 in2) 216 mm (8.5 in)

Master Cylinder (combined servo assistance) Number of Cylinders 2 Type

Compensated master cylinder

Piston Diameter (each)

22.22 mm (0.875 in)

Parking Brake Type Disc Diameter

Manually Adjusted Caliper, cable operated, mounted on transmission output 279.4 mm (11 in)

Note: Because the service brakes are located in the rear axle, instructions for dismantling and assembly are shown in the Transmission Section (Rear Axle Brakes).

9803/3270

Issue 2*

Section G

Brakes

Section G

Descriptions

2-1

Compensating Master Cylinder 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. Note: Dual pedal braking is applicable only to 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 displacement between cylinders will be minimal and the brakes will be applied evenly.

C

2-1

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 cylinder will vary and some form of compensation 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 would be applied before brake H1. Therefore master cylinder A begins to compensate for master cylinder A1. Fluid is displaced from A to A1 via bridge pipe M until the pressures are equalised. In this condition both 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 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 associated pipework, thus braking one wheel only. With valve stem G at maximum travel, further movement of plunger E causes valve K to lift off its seat. Fluid is displaced through drillings P from the active cylinder A via bridge pipe M to passive cylinder A1. Valve K1 in the passive cylinder is held on its seat by the displaced pressurised fluid.

M

N1

H1 A1

B1 H

J

A

F

G

K E

D

B

P N A265570

A265570

9803/3270

Issue 1

Section G

Brakes

Section G 5-1

Fault Finding

5-1

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

1

Master cylinder fault.

1

Check master cylinder in single and coupled pedal modes to identify fault area, service as required.

2

Friction/counter plate distortion.

2

Check friction/counter plates.

1

Air in hydraulic system.

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


3

Renew friction/counter BOTH sides.

B

One or both brakes do not apply. (Brake travel not excessive, brakes not pulling to one side).

Pedal travel excessive (but not touching floor).

plates

-

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.

1

Inspect pedal off/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.

4

Check/renew brake pipework.

pivot.

Free-

Items 5 to 7 are for machines fitted with servo assisted brakes only:

E

F

G

Pedals touch floor under constant pressure - no fluid loss.

Pedals touch floor under constant pressure - and fluid loss.

Pulling to one side when pedals locked together.

9803/3270

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.

7

Renew servo unit.

1


1


2


2


3

Air in hydraulic system.

3

See item B.1.

1

External fluid leaks.

1

Visually check brake circuit for fluid loss, service as required.

2

Internal fluid leaks.

2

See 'Brake Piston Seal Leakage Test' on page G/5-4.

1

Compensating working.

1

Inspect master cylinder compensating operation. Check if blockage in bridging pipe. Service as required.

feature

not

plates

-

Issue 1

Section G

Brakes

Section G 5-2

Fault Finding

5-2 FAULT

POSSIBLE CAUSE

G

2

Braking system inoperative on 2 one side.

Unlatch pedals to test circuits individually.

3

Friction plates worn beyond limits 3 or distorted on one side.


4

Badly adjusted push rods.

Adjust push rod (1mm minimum).

Pulling to one side when pedals locked together (cont'd).

*5

H

J

Poor braking (not pulling to one side).

One or both brakes not releasing.

9803/3270

Servo operating adjustment.

ACTION

rod

4 out

of 5

6

plates

-

Adjust servo operating rod.

6

Annular piston fault (see item J6).

1

Friction plates worn beyond limits 1 or distorted on one side.


2


2


3

Annular piston fault (see item J6).

3

See item J6.

4

Incorrect/low axle oil.

4

Fill axle with correct type of oil.

5

Vacuum failure (machines fitted 5 with servo assisted brakes only).

1

Brake pedal spring fault.

2

Master cylinder fault (plunger 2 stuck in bore).

Service as required.

3

Blocked hole in master cylinder 3 reservoir cap.

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 6.1 Check that correct brake fluid has been used (incorrect fluid could swell axle. 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.

8

Friction/counter plates not free on 8 splines and/or dowels.

1

7

See item J6.

Inspect vacuum service as required.

plates

-

source/pipes,

Fit a new spring.

Check and renew pipes as required. Check friction/counter plates for free movement, replace if required BOTH sides.

Issue 2*

Section G

Brakes

Section G 5-3

Fault Finding

5-3 FAULT

POSSIBLE CAUSE

K

Poor braking when hot.

1

Moisture in system vapourizing 1 when axle is hot.

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 1 type of axle oil.

Change axle oil.

2

Axle oil loss.

2

Refill axle with correct oil and check for leaks.

3 4

Friction plates worn beyond limits. 3 Friction/counter plates in poor 4 condition.

Renew friction/counter plates. Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable).

1

Slight cut or nick in the brake 1 piston seal, see 'Brake Piston Seal Leakage Test' page G/5-4.

Strip axle, replace seal.

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.

M

Fluid loss when machine standing, for instance - overnight (see note).

ACTION

Note: Confirm fault is as indicated by checking that the pedals DO NOT touch floor under constant pressure.

9803/3270

Issue 2

Section G

Brakes

Section G

Fault Finding

5-4

5-4

Brake Piston Seal Leakage 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.

5

Repeat steps 1 to 4 for the opposite brake piston seal.

6

Reconnect all brake pipes and bleed the brake system as recommended on page G/11-1.

! 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 2

3

Remove and cap brake piston feed pipe A. Fill the brake piston housing with JCB Light Hydraulic Fluid. Check for severe piston seal damage: 3.1 Install a hand pump fitted with a 0 - 40 bar (0 600lbf/in2) 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/in2). 3.2 Use the hand pump to generate a pressure in the brake piston housing. 3.3 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: 4.1 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. 4.2 Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid 4.3 Using a suitable pen, mark the level line of the brake fluid on the tube, as shown at C. 4.4 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.

S159830

9803/3270

Issue 1

Section G

Brakes

Section G 11 - 1

Brake System

11 - 1

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

Fill the master cylinder reservoir with the correct fluid (see Lubricants, page 3/1-2), and ensure that throughout the bleeding process the level is not allowed to fall below the MINIMUM mark. Unlatch the pedals, and bleed each brake separately as follows: Right Hand Master Cylinder 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. Open the brake bleed screw and apply full pedal strokes of the right hand brake pedal until all air is expelled. Close the brake bleed screw with the pedal fully depressed. Left Hand Master Cylinder Repeat procedure as for 'Right Hand Master Cylinder' but use left hand bleed screw and pedal. Bridge Pipe 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. 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.

A

Open the bleed screw and apply full pedal strokes of the brake pedals until all air is expelled. Close the bleed screw with the pedals fully depressed. Repeat the procedures as necessary. Top up the reservoir to the full mark.

S107710/1

9803/3270

Issue 1

Section G

Brakes

22 - 1

Parking Brake Calliper

22 - 1

*

Section G

Testing the Parking Brake SAFETY NOTICE: Ensure all routine health and safety precautions are observed before operating machines.

! WARNING Do not use a machine with a faulty parking brake. 3-2-3-10

! WARNING Before testing the parking brake make sure the area around the machine is clear of people.

! CAUTION

2-2-4-5

Non approved modifications to axle ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.

1

Enter the machine. Fasten your seat belt and park the machine on a level dry surface.

3-2-3-11

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.

5

6

3

2

4

! WARNING

P

1

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 either page G/22-2 or G/22-3 whichever is applicable.

9803/3270

S252511

Issue 2*

Section G

Brakes

Section G 22 - 2


22 - 2

Parking Brake Adjustment

Parking Brake Type 1

! CAUTION

1

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.

Checking and Adjust the Pad Position Measure the pad thickness. If the friction material B is 3mm (0.125in) or less always fit a new set of pads. Check that the pads just touch the disc, shown at A, with the parking brake disengaged (lever horizontal).

4-2-1-1/2

If necessary, adjust the pad position by turning nut D. Turn the nut clockwise to close the pads onto the disc.

! 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).

2

Take Up the Cable Slack a Disengage the parking brake (lever horizontal). b Turn handle grip E clockwise, half a turn. c Test the parking brake, see page G/22-1. d If the brake fails the test, repeat Steps 2a, 2b and 2c.

! WARNING Over adjustment of the parking brake could result in the parking brake not fully releasing 0011

B

D E

C

F

A

A350020

9803/3270

S260240

327060

Issue 5

Section G

Brakes

22 - 2A

Parking Brake Caliper

22 - 2A

Renewing the Brake Pads

*1

Section G

Make the machine safe.

! 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

2

Disengage the parking brake lever, (lever horizontal). Turn handle grip to bring pin central in its slot.

3

Release the parking brake cable.

4

Remove the calliper adjuster.

5

Release nut/bolts sufficiently to disengage spring from callipers.

6

Undo and discard brake pad retaining nuts.

7

Remove both brake pads.

8

Pull brake callipers apart.

9

Remove and discard brake retaining bolts, fit new bolts.

10

Fit new brake pads

11

Fit and tighten brake pad retaining nuts to 6Nm (4.4lbf ft).

12

Engage spring in brake callipers and tighten bolts so that the callipers move freely (14Nm, 10.32lbf ft).

13

Reconnect brake cable.

14

Fit adjuster and tighten until the pads just touch the brake disc with the parking brake lever disengaged (lever horizontal).

15

Test the handbrake as detailed on page G/22-1.

2

5 5

8

7

9

6

8

4 9

3 9

12 14Nm (10.32lbf ft) 12 993/23600 452/02700

12

10 11

14

14 15/920160

A373331

15/920159

13 11 6Nm (4.4lbf ft) 9803/3270

Issue 2*

Section G

Brakes

Section G 22 - 3


22 - 3

Parking Brake Adjustment (continued) Lever Adjustment Type 2 1

Cable Adjustment Type 2

! WARNING

Disengage the parking brake (lever horizontal).

2

Turn handle grip E clockwise, half a turn.

3

Test the parking brake, see page G/22-1.

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.

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

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. Always renew a worn or damaged cable.

F

E

1

Disengage the parking brake (lever horizontal).

2

Turn hand grip G 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. Make final adjustments at the park brake lever if the brake fails the test. See Lever Adjustment.

A350020

B

B

H H

C 2

G

F

A326154

A350021

9803/3270

Issue 4

Section G

Brakes

22 - 4


22 - 4

Dismantling and Assembly Type 1

Dismantling The numerical sequence shown in the illustration 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

Section G

Assembly Fit shims 2 to align the parking brake calliper centreline to within ±0.5 mm (0.020 in) of the brake disc centreline. Renew the pads if the thickness of the friction material is 3mm (0.125 in) or less.

! WARNING

Lightly grease all pivots and working surfaces, taking care to avoid grease contacting the brake pads.

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.

Tighten nut 6 sufficiently to allow lever 8 to move freely with minimum side clearance.

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.

Torque Settings Item 1 11 16

Nm 118 20 6

kgf m 12.0 2.0 0.6

lbf ft 87 15 4.4

13-3-1-3

@

2

1

3 £

!

7 &

^ $

%

9

^

0

6

4 5

9803/3270

8

S210860

Issue 2

Section G

Brakes

Section G 22 - 5


22 - 5

Removal and Replacement Type 2 ! 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

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

If there is no adjustment at the lever or the calliper, change the brake pads. 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.

Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

3

Renew the cable if worn or damaged.

13-3-1-3

4

If there is insufficient adjustment after fitting new pads change the brake cable.

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

Removal 1

Release the parking brake lever (lever horizontal).

2

Disconnect clevis A, note which of the three holes on the lever is used.

3

Undo locknuts B and disconnect the cable from the bracket.

4

Support the calliper and remove the two mounting bolts and hardened washers C. Lift the calliper clear of the brake disc.

Note: Do not remove transmission mounting bracket D unless it needs to be renewed.

A

B C

C

Pad Removal See Dismantling page G/22-7 for parts identification. 1

Press carrier side pad 1 into housing 15 and remove. Ensure any residual silicone used for pad retention during assembly is removed.

2

Carefully lever pad 2 from the rotor 9 using a flat blade screwdriver. Take care to prevent damage to the plastic clip in the centre of the rotor.

9803/3270

D

326154 A326154

Issue 1

Section G

Brakes

Section G 22 - 6


22 - 6

Removal and Replacement Type 2

D

Replacement Replacement is the reverse of removal. See Dismantling page G/22-7 for parts identification. 1

Fit pad 2. Position the lever side pad 2 on the face of the rotor 9 and carefully press in place on the plastic clip in the centre of the rotor.

2

Fit carrier side pad 1. 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. Fit new mounting bolts C with hardened washers, see page G/22-10, tighten to 255 Nm (188 lbf ft).

4

Make sure floating parts move freely and that all other parts are mounted securely. Tighten all mounting bolts to the recommended torque figures.

5

Insert cable into bracket D, do not tighten locknuts B at this stage as the brake will need adjusting, see step 7.

5

Refit the clevis to the top hole in the operating lever E.

6

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.

7

Adjust the parking brake (see Lever Adjustment and Cable Adjustment). Never unscrew the clevis to adjust the cable.

B

C

E

C

A326154 326154

Torque Settings Item C

Nm 255

9803/3270

lbf ft 188

Issue 1

Section G

Brakes

Section G 22 - 7


8

14

15

13 13

12

13

13

12

11

10

2

9

1

22 - 7

5 3

4

Carrier Side Pad Lever Side Pad Bolt Anti-rotation Clip Washer Washer Lever Spring Rotor Ball Spacer Ball Bearings Mounting Bush O-ring Shaft Seal Housing

7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

6

Component Listing:

228362

9803/3270

Issue 1

Section G

Brakes

Section G


22 - 8

22 - 8

Dismantling and Assembly Type 2 Dismantling

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.

! 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.

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.

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. See Calliper Removal.

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.

9803/3270

Issue 1

Section G

Brakes

Section G 22 - 9


22 - 9

Dismantling and Assembly Type 2 (Continued) Assembling 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.

Y

X

A348331

10 Fit the new brake pads. See Calliper - Replacement. 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. See Calliper - Replacement.

14

Adjust the parking brake. See Lever Adjustment and Cable Adjustment.


Nm 13-16

9803/3270

lbf ft 9-12

Issue 1

Section G

Brakes Parking Brake Calliper

22 - 10

Section G 22 - 10

Torque Figures Type 2 The illustration shows a typical installation. Where appropriate, the grade of bolt is indicated either in the text or in parenthesis eg. (10.9). Refer also to relevant dismantling and assembly procedures.

Caliper Mounting Bolts (10.9) Tuflok Bolt 255 Nm (188 lbf ft)

Hardened Washer

Transmission Mounting Bracket Bolts (12.9) Verbus Ripp 8 off Powershift 7 off Syncro Shuttle 166Nm (122 lbf ft) Always fit new bolts

Spindle Bolt 13-16 Nm (9-12 lbf ft) A350440

9803/3270

Issue 1

Section G 23 - 1

Brakes

Section G

Service Brakes

23 - 1

Service Brakes - 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 shown in the Transmission section (Rear Axle Brakes).

A

A264180 A264180

9803/3270

Issue 1

Section G

Brakes

Section G 30 - 1

30 - 1

S267280

L

AJ B

K 327340

9803/3270

Issue 4

Section G

Brakes

Section G 30 - 2

Master Cylinder and Servo Unit

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 Lift away cab floor mat from base of front control consoles.

2

Adjust measurement J by screwing domed bolt K in/out as required, secure in position with Loctite 603.

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.

2

Remove bolts A and take off the steering pedestal cover B.

3

Loosen and remove brake pipe unions C, plug and cap to prevent loss of fluid and ingress of dirt.

Fill the brake system with JCB Light Hydraulic Fluid, bleed the system as described on page G/11 - 1 and set the pedals (see below).

4

Remove the brake pipes from the master cylinders: master cylinders bridging pipe D; axle feed pipes E and reservoir supply pipes H.

Note: 4WS machines do not have dual pedal braking. Procedures described still apply to a single pedal application.

5

Remove the brake pedals clevis F and disengage the brake pedal from the servo unit (both pedals).

4

Unlatch pedals and ensure that pedal pads are level with each other and fully back against their stops.

6

Loosen and remove the servo unit retaining nuts G (both units).

5

Adjust pedal linkages for free movement to give 1 mm (0.040 in) on each pushrod.

7

Remove the left and right hand master cylinder and servo units.

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 as detailed in the Service Manual and check the brakes operate correctly and that machine stops in a straight line.

8

Latch pedals and check for straight line braking; if satisfactory straight line braking cannot be achieved refer to fault finding, page G/5 - 1.

BRAK 1-1

3


* New master cylinders with increased compensation were introduced in July 2000. * Brake cylinders with differing compensation values can be mixed, units do not require replacing as pairs. Where units are mixed the the lower compensation cylinder controls the brake system compensation.

* A colour coding has L has been added to aid identification

Torque Settings Item

Nm

kgf m

lbf ft

H

30-34

3.0-3.5 22-25

of the new brake master cylinders. 214e only Servo assisted Non servo

White Black Green

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).

9803/3270

Issue 2*

Section G

Brakes

Section G 31 - 1

Master Cylinder and Servo Unit

31 - 1

Dismantling and Assembly The servo unit (not shown) is a non serviceable part. Replace a faulty servo unit with a new one When Dismantling Remove circlip 1 and washer 2. Shake the cylinder, or use compressed air, to eject piston assembly 3. Examine the working surfaces of piston and cylinder. If these are not in perfect condition the master cylinder assembly must be renewed. Only seals and 'O' rings are serviceable. Replace a faulty master cylinder and piston assembly with new ones.

* Note: Seal kits are longer available for the later master cylinders, the only servicing permitted is a major repair kit which comprises of a full piston assembly.

When Assembling

! WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. BRAK 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. Take care not to damage the machined faces of piston 3 when assembling new seal 5, which must be located as shown at A.

S264190

S151280

9803/3270

Issue 2*

Section H

Steering

Section H

i

i

Contents

9803/3270

Page No.

Technical Data Steer Hydraulics (4WS Machines) Steer Hydraulics (2WS Machines)

1-1 1-2

Schematics 2WS Machines 4WS Machines

3-1 3-2

Fault Finding

4-1

Machine Steer Circuit Description 2WS Machines 4WS Machines

10 - 1 10 - 2

Priority Valve Removal and Replacement Dismantling and Assembly

15 - 1 15 - 1

Hydraulic Steer Unit Removal and Replacement Dismantling and Assembly

16 - 1 16 - 1

Steer Mode Valve Removal and Replacement Dismantling and Assembly

17 - 1 17 - 2

Steer System Pressure Testing

25 - 1

Steer System Bleed Procedure

26 - 1

Power Track Rod Removal and Replacement Link Arms - Removal and Replacement Rams - Dismantling and Assembly

30 - 1 31 - 1 32 - 1

Proximity Switches Setting Procedure

35 - 1

Issue 1

Section H

Steering

Section H

Technical Data

1-1

1-1

Steer Hydraulics (4WS Machines) System Type Hydraulic Supply Control Unit Type

Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve

ORBITROL VALVE - FIG 1 Model - Volumetric Displacement - Relief Valve - Check Valve - Shock Valve - Relief Valve Operating Pressure (at 1500 revs/min) - Shock Valve Operating Pressure

160 OSPC 160 cc/rev Fitted Fitted Fitted 120 ± 3 bar 122 ± 3.5 kgf/cm2 175 - 190bar 178 - 199 kgf/cm2

PRIORITY VALVE - FIG 2 Stand by Pressure

7 bar

LS

7.1 kgf/cm2

1740 ± 50 lbf/in2 2538 - 2756 lbf/in2

102 lbf/in2

EF

P

LS

LS

A263810

FIG 1

9803/3270

FIG 2

Issue 1

Section H

Steering

Section H

Technical Data

1-2

1-2

Steer Hydraulics (2WS Machines) System Type Hydraulic Supply Control Unit Type

Full Power Hydrostatic From Main Hydraulic Pump Via Priority Valve Load Sensing With Integral Relief Valve

ORBITROL VALVE - 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)

200 OSPC 200 cc/rev Fitted Fitted Fitted 120 ± 3 bar 122 ± 3.5 kgf/cm2 175 - 190bar 178 - 199 kgf/cm2 250 OSPC 250 cc/rev Fitted Fitted Not Fitted 120 ± 3 bar 122 ± 3.5 kgf/cm2

PRIORITY VALVE - FIG 2 Stand by Pressure

7 bar

LS

7.1 kgf/cm2

1740 ± 50 lbf/in2 2538 - 2756 lbf/in2

1740 ± 50 lbf/in2

102 lbf/in2

EF

P

LS

LS

A263810

FIG 1

9803/3270

A263820

FIG 2

Issue 1

Steering

Section H

Section H

Schematics

3-1

3-1

Steer Hydraulics (2-Wheel Steer Machines) Component Key P1 P2 P2A S T 6 7 10 42 43 44

Pump, Main Section Pump, Secondary Section Pressure Test Point Suction Line Tank In-tank Filter Priority Valve Front Power Track Rod Steer Control Unit Shock Valve Steer Control 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.

T

6

(L)

43

(R)

S

42 (LS)

10

P2 P1

44 (T)

(P)

(CF)

(EF) (LS)

(P)

7 P2A

9803/3270

Issue 1

Steering

Section H

Section H

Schematics

3-2

3-2

Steer Hydraulics (All Wheel Steer Machines) Component Key P1 P2 P2A S T 6 7 8 10 11 42 43 44

Pump, Main Section Pump, Secondary Section Pressure Test Point Suction Line Tank In-tank Filter Priority Valve Steer Mode Valves Assembly Front Power Track Rod Rear Power Track Rod Steer Control Unit Shock Valve Steer Control 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.

T

6

10 (L)

43

(R)

S

42 (LS)

8

P2 P1

44 (T)

(P)

(CF)

(T)

(B)

(P)

(A)

(EF) (LS)

(P)

7 P2A 11

9803/3270

Issue 1

Section H

Steering Fault Finding

4-1


Introduction

4-1

Steering wheel difficult to turn

4-1

Steering wheel turns on its own

4-2

Machine will not turn when the steering wheel turned.

4-2

Steering fails to respond to selected mode (4WS Machines only)

4-3

Fault

Steering wheel difficult to turn.

4-1


1

Section H

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


2


3


4


5


6


7


Probable Cause

Action

Tyres not inflated to correct pressure

Inflate tyres to correct pressure





Air in the hydraulic system.

Bleed system - bleed the load sense line.

Low pump flow.




Worn or damaged parts in the steer control valve.

Remove and inspect.

....... continued

9803/3270

Issue 1

Section H


4-2 Fault 1

Section H

Steering wheel difficult to turn. (continued)

4-2

Probable Cause

Action



Steer mode valve not operating correctly (4WS Machines only)

Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required

Mechanical failure

2

3

Steering wheel turns on its own.

Machine will not turn when the steering wheel turned.

Check for damaged axle components, such as rams, trackrods, linkages etc.

Dirt in the steer control unit (causing sleeves to stick open)

Clean and inspect unit.

Steer control valve centring springs damaged, broken or missing.

Check unit.

Steer control valve - position of rotor to shaft slot incorrect.

See page H/16-4, step 9. Correct as required.





Air in the hydraulic system.

Bleed system - bleed the load sense line.

Low pump flow.




Worn or damaged parts in the steer control valve.

Remove and inspect.



9803/3270

Issue 1

Section H


4-3 Fault 3

Section H

Machine will not turn when the steering wheel turned (continued).

Probable Cause Steer mode valve not operating correctly (4WS Machines only)

4-3 Action Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required

4

Steering fails to respond to selected mode (4WS Machines only)

Mechanical failure

Check for damaged axle components, such as rams, trackrods, linkages etc.

Steer column splined shaft not fully engaged in steer valve.

Check shaft engagement.

Power track rod failure

Check power track rod for signs of damge, leaks etc.

Selector switch faulty

Check selector switch, replace as required

Proximity switches not operating correctly

Check setting of proximity switches, reset or replace switches as required.


Check if spools sticking, rectify as required Check if solenoids operating, replace solenoids as required.

9803/3270



Electrical failure

Check relevant electrical connectors, if problem still persists, do a wiring continuity check on relevant circuits.

Issue 1

Section H

Steering

Section H

Machine Steer Circuit Description

10 - 1

10 - 1

2 Wheel Steer Machines The main components of the steering system are the priority valve 7, load sensing steer unit 42, hydraulic tank and the front power track rod 10. When the steering wheel is turned, a pressure demand is sensed at the priority valve via load sensing line LS. Oil from the second section of the hydraulic pump is then distributed via the priority valve to the steer unit 42, which then directs the oil to the front power track rod 10 until the required steering lock is achieved. When the steering lock is held, the pressure signal LS ceases, full pump flow from the second section of the hydraulic pump is now distributed to the main hydraulic circuit via the priority valve. Maximum steering system pressure is controlled by a relief valve located in the steering unit 42.

42 LS

7

S266390

9803/3270

10

Issue 1

Section H

Steering

Section H

Machine Steer Circuit Description

10 - 2

10 - 2

4 Wheel Steer Machines The main components of the steering system are the priority valve 7, load sensing steer unit 42, hydraulic tank, front power track rod 10 and rear power track rod 11. When the steering wheel is turned, a pressure demand is sensed at the priority valve via load sensing line LS. Oil from the second section of the hydraulic pump 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 trackrod 11 via steer mode valve 8. When right turn is selected, oil is delivered directly to the front power trackrod 10. When the steering lock is held, the pressure signal LS ceases, full pump flow from the second section of the hydraulic pump is now distributed to the main hydraulic circuit via the priority valve. Maximum steering system pressure is controlled by a relief valve located in the steering unit 42.

8 42

11

LS

7

S266400

10 9803/3270

Issue 1

Section H

Steering

Section H 15 - 1

Priority Valve

15 - 1



! 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.

For assembly the sequence should be reversed. When Dismantling

2-3-2-2

The priority valve is mounted on the right hand side chassis member, behind the diesel tank. It is attached to the chassis member by one bolt A, and is accessible from below. When replacing always renew sealing washers 2, 4, 6, and 10.

Press out the spool item 12 using a nylon pin. Take care not to damage the bores of the valve. When Assembling 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: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter. Torque Settings

9

Item 7 9

10

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.

11 3

A

Nm 50 50

lbf ft 37 37

4

2

1

6 5

12 8 7

S263840

9803/3260

Issue 1 SXXXXXX

SXXXXXX

Section H

Steering

Section H

Hydraulic Steer Unit

16 - 1

16 - 1


When Replacing

When Removing

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.


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. Turn the steering wheel to the left and to the right several times to vent system pressure. Remove bolts A and take off the steering pedestal cover B to gain access to the steering unit. Disconnect and cap all hydraulic hoses from the steering unit. Label the hoses to ensure correct refitting.

! WARNING

INT-3-1-10/1

Replacement is a reversal of the removal sequence. Make sure that the hoses are correctly installed. Bleed the steering system, see page E/26 - 1. If a new steering unit has been fitted then the system relief valve must be tested for correct pressure setting, see page E/25 - 1. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have sealant (Loctite 577) applied to the threads of the adapter.

Take hold of the steering unit, loosen and remove bolts C. Lift the steering unit from the machine.

9803/3270

Issue 1

Section H 16 - 2

Steering Hydraulic Steer Unit

Section H 16 - 2

S10221A

9803/3270

Issue 1

Section H 16 - 3

Steering

Section H

Hydraulic Steer Unit

16 - 3

Hydraulic Steering Unit Dismantling Use the numerical sequence on page H/16-2 as a guide to dismantling. 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. 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. Assembling Note: The unit illustrated in the following sequence represents a typical Danfoss valve. The relief valve (items 25 to 28) and shock valves (items 29 to 35) are not therefore shown in the illustrations. 1

Fit spool 15 into sleeve 12, aligning slots for centring springs 13 and checking that the small marks X are aligned. Ensure that three slots in spool partially 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 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.

S229690

9803/3270

Issue 1

Section H 16 - 4

Steering Hydraulic Steer Unit

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.

Section H 16 - 4

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 valve is preset at 120 bar (122 kgf/cm2, 1740 lbf/in2) but the setting should be rechecked after fitting the steering unit to the machine.

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 and Degreaser, allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat threads of screw 31 with JCB Lock and Seal. Assemble screw to depth measured during dismantling (see page H/16-3) then fit plug 29 and washer 30.

9803/3270

Issue 1

Section H

Steering

Section H 17 - 1

Steer Mode Valve

17 - 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


When Replacing


Replacement is a reversal of the removal sequence. Make sure that the electrical solenoid connections are refitted in the correct position. Make sure that the hoses are correctly installed. The hose connections from the steer valve assembly are as follows: P B A T

When Removing 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. Turn the steering wheel to the left and to the right several times to vent system pressure. The steer valve assembly is fitted to a bracket which is mounted on the right hand side of the machine in front of the rear axle.

-

to orbitrol steer unit (L port) to rear power track rod (left side) to rear power track rod (right side) to front power track rod (right side)

Note: The steer valve ports should be stamped 'P', 'B', 'A' and 'T'. Left and right hand are as viewed from the rear of the machine. Bleed the steering system, see page H/26 - 1.

Disconnect the electrical solenoid connections, the wires should be identified A, B, C and D as shown. Disconnect and cap all hydraulic hoses from the steering valve assembly. Label the hoses to ensure correct refitting. Take hold of the steering valve, loosen and remove bolts E. Lift the steering valve and its retaining bracket from the machine.

A

C

B

E D

9803/3270

Issue 1

Section H

Steering

Section H 17 - 2

Steer Mode Valve

17 - 2


When Assembling Renew all 'O' rings.

For assembly the sequence should be reversed. Lubricate parts with JCB Special Hydraulic fluid before assembling.

When Dismantling Before dismantling scratch an alignment mark X along the faces of the solenoid valves and the manifold block. Take care not to lose the detent balls A from items 16 and 18.

Use the alignment marks X (see dismantling) to ensure that the solenoids and the manifold block are assembled correctly. Torque Settings Item 1

Nm 7.1-9.1

lbf in 63-80

1

S263950

16 15 18

17

A

11 9 3 2

8

4 7

12 10

19

14

5

6

13 S263960

9803/3270

Issue 1

Section H

Steering Steering System - Pressure Testing

25 - 1

Section H 25 - 1

Steering System - Pressure Testing 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. 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.

A

GEN-1-2

The pressure test point for the steering circuit is fitted next to the priority valve as shown. Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test adaptor A. 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 given in Technical Data.

S263940

Note: The steering wheel must be held on full lock whilst the gauge reading is being checked. If necessary, adjust the pressure setting by removing plug B, on the orbitrol steering unit. Adjust screw C using an 'allen key' until the correct pressure is shown on the gauge. Refit plug B.

S147680A

9803/3270

Issue 1

Section H 26 - 1

Steering Valves

Section H 26 - 1

Steering System - Bleeding Procedure Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows. With the engine running, this 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


6

Select 4 Wheel Steer (a) Turn steering wheel to left, until front wheels are fully locked to the left.

7


8

Select 4 Wheel Steer (a) Turn steering wheel to left, until the front and rear wheels are fully locked.

9803/3270

Issue 1

Section H

Steering

Section H 30 - 1

Power Track Rod

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.

B C

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

A258510

When Removing Disconnect and cap hydraulic hoses to prevent loss of fluid and ingress of dirt. Label hoses for identification and correct refitting. 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. Remove the four fixing bolts D. When Replacing Replace the power track rod by reversing the removal procedure. On 4WD machines make sure that the split pin is fitted. After connecting hoses check hydraulic fluid level, if necessary top up. A258490

A

Bleed hydraulic steering system, see page H/26-1. Torque Settings See Technical Information 2/209 *

D D D

9803/3270

D A258500

Issue 2*

Section H

Steering

Section H 31 - 1

Power Track Rod

31 - 1

Link Arms Removal and Replacement

M L

A258480

A J

F

E N

H

G

B K

M

J

F

E A258470

S300370

X C

C

Y 9803/3270

S258450

Issue 3

Section H

Steering

Section H 31 - 2

Power Track Rod

31 - 2

Link Arms (cont’d) Removal and Replacement (cont’d) Removal

Replacement

If the power track rod ram is to be dismantled, or the link arms replaced, proceed as follows:

Note 1: If the power track rod ram is to be dismantled, carry out the procedure (see Power Track Rod Ram in this section) before replacing/renewing the link arms.

1

Fix the assembly on a locally made strip/rebuild bench as shown.

2.1 Using two suitable open ended spanners at L and M react against each other until one ball joint unscrews. 2.2 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.

Replacement is the reverse of removal but note the following: 1

Remember to fit the target disc G (where applicable).

2

Use Threadlocker & Sealer on the trackrod link arms.

3

If the link arms have been renewed, the wheel alignment must be checked. 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.

2.3 By reacting against the spanner at N and M undo the other ball joint. Note: 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. Note: The piston rod operates at full length, any damage to the surface will cause fluid leaks. DO NOT attempt to grip the rod diameter with pipe grips etc. 3

Repeat the procedure for the remaining link arm assembly.

4

Where applicable remove the target disc G.

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 2: AWS machines shown at A. 2 wheel steer machines shown at B. 4

Check the proximity switch setting (where applicable). See Proximity Switches, Setting Procedure.

Note: If the inner or outer ball joints need to be renewed, then a replacement link arm assembly must be fitted.

* Torque Settings 2WS /4WD

C 180 Nm (132 lbf ft)

H 45/50 Nm (33/36 lbf ft)

E 240/260 Nm (177/184 lbf ft)

2WS/4WD

C 140/150 Nm (103/110 lbf ft)

K 300 Nm (221 lbf ft)

E 240/260 Nm (177/184 lbf ft)

AWS/4WD

C 270/280 Nm (199/206 lbf ft)

H 70/85 Nm (51/62 lbf ft)

E 450 Nm (331 lbf ft)

AWS/4WD

C 270/280 Nm (199/206 lbf ft)

K 390/410 Nm (287/302 lbf ft)

E 450 Nm (331 lbf ft)

2WS/2WD

C N/A

K 240/260 Nm (177/184 lbf ft)

E 240/260 Nm (177/184 lbf ft)

9803/3270

Issue 3*

Section H

Steering

Section H 32 - 1

Power Track Rod

32 - 1

Rams Dismantling and Assembly

A

1 A258580

7 6

5 8

3 4

D

3

5

8

S258430

1 2 6 7

B

C

A258590

9803/3270

Issue 1

Section H 32 - 2

Steering

Section H 32 - 2

Power Track Rod

Rams (cont’d) Dismantling and Assembly (cont’d)

When Assembling


Clean the threads of the end caps and cylinder using a wire brush.


Use a JCB Cleaner & Degreaser to ensure that all threads are free from grease, hydraulic oil and Loctite. Allow 15 minutes for solvent to dry before applying Loctite.

When Dismantling Fix the ram assembly on a locally manufactured strip/rebuild bench as shown at A. Remove both end caps, using a special spanner (see Service Tools, Section 1). Pull the piston rod assembly from the cylinder. Note: DO NOT allow the piston rod to come into contact with the cylinder bore. The cylinder bore may be damaged by careless dismantling. 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 that the piston head cannot be removed from the rod. If there is damage to the rod or piston head, replace the complete assembly. 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: If burrs are evident on the ends of the piston rod at positions C or D remove by careful filing. Note that both end cap assemblies are the same, dismantle as follows: Remove the end cap seal, ‘O’ ring and wiper seal. The bearing bush 8 can be renewed if necessary. However, time will be saved if a complete end cap and bush assembly is obtained.

Ensure that lubricants used during assembly do not come into contact with Loctite. * Refer to the JCB Ram Sealing Procedure for the correct method of fitting seals to the end cap and piston head. 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. Apply Loctite Activator N to threads of the end caps and cylinder. Allow Activator to dry for 15 minutes before bringing into contact with the Loctite. Note: Neither Loctite nor Activator must be allowed to contact seals, bearing rings or ‘O’ rings. Apply Loctite 932 to threads of the ends caps, fit new ‘O’ ring 5. Ensure that there are no burrs at the ends of the piston rod, see Dismantling. 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: If hydraulic oil contacts uncured Loctite a weakening of the bond will result. Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure times apply at 20 °C and are the minimum periods between assembly and filling the ram with oil. Loctite 262 or 932 with Activator N - 1 hour Loctite 262 or 932 with Activator Y - 2 hours Torque Settings Item 1

Nm 678

kgf m 69.2

lbf ft 500

Note: 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.

9803/3270

Issue 2*

Section H

Steering

Section H 35 - 1

Proximity Switches

35 - 1

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

C

GEN 3-2

The proximity switch setting procedure is the same for both the front and rear axles. Note that 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.

E Y

E D A

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.

A B

X X

A258170

9803/3270

Issue 1

Section K

Engine

Section K

i

i

Contents Technical Data Engine Removal & Replacement

* Fuel Lift Pump

9803/3270

Page No. 1-1

15 - 1 16 - 1

Issue 2*

Section K

Engine

Section K

Technical Data

1-1

1-1

Type

1000 Series 4 cylinder Engines AB - Turbocharged AA - Naturally Aspirated AK - Turbocharged AM - Turbocharged and Intercooled AR - Naturally Aspirated

Engine Build List Number

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

100mm (3.937 in) 103mm (4.055 in) 127mm (5.000 in) AB, AA, AK, AM 4 litres (243 in3) AR 4.23 litres (258 in3) Compression Ratio AB 16.0:1 AA 16.5:1 AK, AM 17.25:1 AR 18.5:1 Compression Pressure 28 bar (400 lbf/in2) [maximum variation between cylinders 3.5 bar (50 lbf/in2)] Injection Sequence 1,3,4,2 Valve Clearance - Cold - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in) Oil Pressure (hot) at maximum speed - AA 2.1 bar (30 lbf/in2) - AB, AK, AM 2.6 bar (40 lbf/in2) - AR 2.0 bar (30 lbf/in2) Maximum Air Cleaner Restriction 559mm (22 in H2O) 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/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)

For further engine details see Engine Service Manual: AA, AB - 9806/0100 AK, AM, AR - 9806/2140

9803/3270

Issue 2*

Section K

Engine

Section K

Removal & Replacement

15 - 1

D

E

15 - 1

B

C

F G

A Y

E

N

Q

Q

M

S H

R

J

L K 9803/3270

P

S24400

Issue 1

Section K 15 - 2

Engine

Section K


15 - 2

Engine Removal and Replacement When Removing

17

Loosen and remove the exhaust silencer retaining bolts, remove the silencer.

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

18

Loosen and remove the retaining clamp for the heater hose. Remove the hose.

Raise the loader arms and fit the loader arm safety strut.

19

Loosen and remove the retaining clamp for the air filter intake hose.

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.

20

Remove the air intake filter. Use tape to close the opening in the air intake manifold, this will prevent ingress of dirt.

21

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.

22

Label and remove all electrical connections, the number of connectors will vary depending on the ancillary equipment fitted to the engine. Typical electrical connectors are: i) starter motor ii) alternator iii) coolant pressure switch iv) coolant temperature sender v) engine oil pressure switch vi) engine temperature sender vii) engine shut off solenoid viii) ether cold start (if fitted) ix) air conditioning compressor (if fitted)

23

If air conditioning is fitted:

1

2

3

Remove the engine side panels

4

Remove the engine cover (including the exhaust stack).

5

Disconnect the battery. When disconnecting the 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 orifices 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 (disconnect top hose at connection Y). 9

Drain the cooling system.

0

Remove the transmission oil cooler hoses E.

11

Remove the radiator top hose and bottom hose.

12

Remove the coolant bottle pipe.

13

Make a suitable alignment mark to allow correct 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 damage the engine fan, note also that the subassembly 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 hydraulic pump driveshaft retaining bolts, remove the pump driveshaft H.

9803/3270

23.1

Remove the belt from the clutch of the air conditioning compressor.

23.2

Disconnect the high and low pressure electrical connectors at the compressor.

23.3

Loosen and remove the air conditioning compressor retaining bolts.

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. 23.4

Put the air conditioning compressor out of the way (do not allow the compressor to ‘hang’ on its hoses).

24

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.

25

Loosen and remove the retaining bolts for the fuel sedimenter, remove the sedimenter K.

......cont’d

Issue 1

Section K 15 - 3

Engine

Section K


15 - 3

Engine Removal and Replacement When Removing (continued)

When Replacing

26

Replacement is a reversal of the removal procedure.

27

28

29

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. If fitted, loosen and remove the ether cold start canister retaining bolts, lift off the canister and retaining bracket assembly. 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. Loosen and remove the rear propshaft to transmission retaining bolts M.

30

On 4WD machines, loosen and remove the front propshaft to transmission retaining bolts N.

31

Remove the access bung located at the base of the transmission. 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).

When mating the transmission/torque converter to engine, ensure that the drive tangs are correctly located in the transmission pump. When the transmission and engine are bolted together and before bolting the flexi-plate to flywheel, rotate the torque converter by hand. The converter should spin freely. Use the access hole in the bottom of the transmission 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. 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 ‘When Removing’. Make sure that the front nose guard and the engine cover are correctly aligned. Refill cooling system using correct mixture of water/antifreeze.

32

If manual transmission fitted, disconnect the gearshift lever from the top of the transmission.

Check engine, coolant and brake oil levels.

33

Use a suitable trolley jack and support the weight of the transmission.

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

Note: Attach a ‘cradle’ to the trolley jack that will evenly support the weight of the transmission. Refer to Special Tools, Section 1.

Make sure that the engine idle speed is correct, adjust as required, refer to Engine Technical Data for speeds.

34

Use a suitable stand and support the weight of the engine.

35

Loosen and remove the transmission mounting bolts Q.

36

Remove the transmission to engine retaining bolts R, pull the transmission and converter clear of the engine, make sure that the converter stays mounted on the transmission shaft.

37

Attach suitable lifting chains to the engine, (see lifting wire assembly 892/00836 in the special tools section). Take the weight of the engine on the hoist.

38

Loosen and remove the engine mounting bolts S (both sides).

39

Lift the engine clear of the machine.

40

Put the engine on a suitable stand, the correct dismantling and assembly procedures are detailed in the engine service manual, publication number 9806/0100.

9803/3270

Torque Figures Item M N P Q R S

Nm 118 79 44 237 98 85

Kgf m 12 8 4.5 24 10 8.7

lbf ft 87 58 32 175 72 63

Description Rear propshaft bolts Front propshaft bolts Flexi-plate to flywheel bolts Transmission mounting bolts Transmission 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. Nm Plastic 4 Aluminium 30

Kgf m 0.4 3.0

lbf ft 3.0 22

Issue 2*

Section K 16 - 1

Engine

Section K

Fuel Lift Pump

16 - 1

An improved fuel lift pump has been introduced for use on JCB four-cylinder 1000 Series diesel engines. The new pump is a one piece assembly and cannot be dismantled. The new pump is interchangeable with the earlier pump. The procedure to remove and fit the new pump has not changed, see Engine Service Manual. Remove and clean fuel inlet strainer 2 when suspected blocked ie. low on power, difficult to start, fuel tank contamination.

A

Cleaning the Strainer 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.

2 3

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.

9803/3270

Issue 1

13547289-J34222BLSRMID344T4349T92229O-Jcb_3cx_4cx_214_215_217_Backhoe_Loader_Service_Repair_Manual_Instant_Download_-_3cx_4cx_460001_To_499999_3cx_4cx_92000

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