jcb_530_533_535_540_sm.pdf

www.WorkshopManuals.co.uk General Information Care & Safety R

Routine Maintenance Attachments Body & Framework

Service Manual

Electrics Controls Hydraulics

LOADALL

Transmission

Models: 530, 533, 535, 540 from Serial No. 767001

Brakes Steering

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND Publication No. 9803/3630

Engine

Purchased from www.WorkshopManuals.co.uk

www.maskinisten.net

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

www.WorkshopManuals.co.uk


www.maskinisten.net


www.maskinisten.net

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB International Training Centre. 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!

How to use this manual The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for all the machine.

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

= =

Attachments Body & Framework

...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section. READ the section contents to locate machine types, machine type identification IS NOT listed on individual pages. All sections are listed on the title page; 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.

This Service Manual covers the following machines: 530 * 533

535 540 * 530FS Plus * 540FS Plus 530FS Super (530 SXL France) 540FS Super (540 SXL France)

9803/3630

Issue 5*




www.maskinisten.net

Section 1

www.WorkshopManuals.co.uk General Information

i

www.maskinisten.net Section 1

i

Contents

Page No.

Identification

1-1

Torque Settings

2-1

Service Tools - Numerical List - Section B - Section C - Section E - Section F - Section H - Section K

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

Sealing and Retaining Compounds

9-1

9803/3630

Issue 3*


Section 1



1-1

1-1

Vehicle Identification Number (VIN)

Engine Identification Number

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

The engine serial number is stamped on a label W which is fastened to the right side of the cylinder block, near the fuel filter.

V

A335321

W

S263330

Explanation of Vehicle Identification Number

SLP540RE0767001

*

A A *B C

D E

B

C D

World Manufacturer Identification Machine Model Year of Manufacture: P = 1993 V = 1997 R = 1994 W = 1998 S = 1995 X = 1999 T = 1996 Y = 2000

Typical Engine Identification Number

E SLP = JCB 540 S 1 = 2001 2 = 2002 3 = 2003 4 = 2004

Manufacturing Location E = England Machine Serial Number 0754001

AA 50261 U 500405 P A B C D E A Engine Type: AA = 4 cylinder naturally aspirated AB = 4 cylinder turbo AR = 4 cylinder naturally aspirated - Low emission AK = 4 cylinder turbo - Low emission B Build Number C Country of Origin

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.

D Engine Sequence Number E Year of Manufacture

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

9803/3630

Issue 3*


Section 1


1-2


1-2

Transmission Identification Number The Transmission serial number is stamped on label Y which is mounted on the side face. The rear axle serial number is stamped on plate X mounted to the front face of the axle. The front axle serial number is stamped on plate Z mounted on the rear face of the axle.

Y

S263370

X

S263350

Z

S263340

9803/3630

Issue 2


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 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7/16 1/2 9/16 5/8 3/4 13/16 15/16

11/8 15/16 11/2 17/8 21/4

Nm 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 (mm) M3 M4 M5 M6 M8 M10 M12

(3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m lbf ft 1.2 3.0 6.0 10.0 24.0 48.0 82.0

0.12 0.3 0.6 1.0 2.5 4.9 8.4

0.9 2.0 4.5 7.5 18.0 35.5 60.5

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

9803/3630

Issue 1


Section 1


3-1


3-1

Service Tools Numerical List 449/03702 449/03705 460/15707 460/15708 1406/0011 1406/0014 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1606/0012 1606/0014 1606/0015 1606/0017 1612/0006 4003/0211 4101/0251 4101/0451 4101/0552 4101/0651 4102/0551 4102/0901 4102/1212 4102/1951 4103/0955 4103/2109 4104/0251 4104/0253 4104/1203 4104/1310 4104/1557 4201/4906 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/50043 816/55038 816/55040 892/00039 892/00041 892/00047 892/00048 892/00049 892/00051 892/00055 892/00056 892/00057

Page No Fitting Adapter 7-3 Adapter 7-3 Banjo Bolt 7-3 Adapter 7-3 Bonded Washer 6-1 Bonded Washer 6-1 Bonded Washer 6-1 Bonded Washer 6-1 Bonded Washer 6-1 Adapter 6-3 Adapter 6-3 Adapter 6-1 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-3 Adapter 6-1 Anti-Seize Paste 9-1 JCB Threadlocker and Sealer 9-1 JCB Threadlocker 9-1 JCB Threadlocker and Sealer (high strgth) 9-1 JCB Retainer (high strength) 9-1 JCB High Strength Threadlocker 9-1 Clear Silicone Sealant 9-1 JCB Multi-Gasket 9-1 JCB Threadseal 9-1 Plastic to Metal Bonder 9-1 Ultra Fast Adhesive - 310 ml (for direct glazing kit) 9-1 JCB Activator (Aerosol) 9-1 JCB Activator (Bottle) 9-1 Active Wipe 205 - 250 g (for direct glazing kit) 9-1 Hand Cleaner 4-1 JCB Cleaner and Degreaser 9-1 Black Primer 206J - 30 ml 9-1 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Blanking Cap 6-2 Pressure Test Adapter 6-3 Adapter 6-1 'T' Adapter 6-2 Pressure Test Adapter 6-1 Pressure Test Adapter 6-1 Spool Clamp 6-2 De-glazing Tool 8-1 'T' Adapter 6-2 'T' Adapter 6-2 'T' Adapter 6-2 'T' Adapter 6-2 Blanking Plug 6-2 Blanking Plug 6-2 Blanking Plug 6-2

892/00058 892/00059 892/00060 892/00071 892/00074 892/00075 892/00076 892/00077 892/00137 892/00179 892/00180 892/00181 892/00223 * 892/00254 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 892/00274 892/00275 892/00276 892/00277 * 892/00279 * 892/00280 892/00281 892/00282 892/00283 892/00284 892/00285 892/00286 892/00295 892/00301 892/00302 892/00333 892/00334 * 892/00346 892/00347 892/00706 892/00801 892/00802 892/00803 892/00807 892/00808

Page No Blanking Plug 6-2 Blanking Plug 6-2 Blanking Plug 6-2 Adapter 6-3 Female Connector 6-2 Female Connector 6-2 Female Connector 6-2 Female Connector 6-2 Micro-Bore Hose 6-3 Bearing Press 7-1 Seal Fitting Tool 8-1 Plastic Boss 8-1 Hand Pump 6-3 Hose 6-1 1 6-3 /4'' BSP Test Point 3 6-3 /8'' BSP Test Point 1 /2'' BSP Test Point 6-3 5 6-3 /8'' BSP Test Point 1'' BSP Test Point 6-3 11/4'' BSP Test Point 6-3 5 6-3 /8'' UNF Test Point 1 6-1 /4'' M BSP 1/4'' F BSP 5 6-1 /8'' M BSP 5/8'' F BSP 3 /4'' M BSP 3/4'' F BSP 6-1 1'' M BSP 1'' F BSP 6-1 Flow Monitoring Unit 6-1 Sensor Head 6-1 Load Valve 6-1 Adapter 6-1 Adapter 6-1 Adapter 6-3 Adapter 6-1 Adapter 6-1 Adapter 6-1 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 6-1 Pressure Gauge 0-600 bar (0-9000 lbf/in2) 6-1 AVO Meter 5-1 Shunt 5-1 Tool Kit Case 5-1 Digital Tachometer 5-1 Hyd. Oil Temperature Probe 5-1 Surface Temperature Probe 5-1 End Float Setting Tool 7-1 Flow Test Adapter 7-3 Flow Test Adapter 7-3 Heavy Duty Socket 7-2 Ram Seal Fitting Tool 6-4 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 6-1 Connector 6-1 Test Probe 6-3 Clutch Spanner for air conditioning compressor 4-3 Rotor Puller Set for air conditioning compressor 4-3 Rotor Installer Set for air conditioning compressor 4-3 Front Plate Puller for air conditioning compressor 4-3 Shaft Protector for air conditioning compressor 4-3

9803/3630

Issue 5*


Section 1



3-2

3-2 Numerical List

Service Tools (cont’d)

Page No

Solid Spacer Setting Tools Numerical List * 892/00812 892/00817 892/00818 892/00819 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/00905 892/00912 892/00914 892/00915 892/00916 892/00920 892/00943 892/00952 892/00956 892/01027 926/15500 992/02800 992/04000 992/04800 992/07603 992/07608 992/07609 992/07610 992/07611 992/07612 992/07613 992/09500 992/09700 992/10100 992/12300 992/12400 992/12600 992/12800 992/12801 993/59300 993/70100 993/85700

Drive Coupling Spanner Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Glass Lifter Folding Stand Long Knife Cartridge Gun Glass Extractor Nylon Spatula Wire Starter Braided Cutting Wire Test Box - SLI and LMI Bevel Box Socket Bevel Box Socket Bevel Box Reaction Block Spring Compressor Flow Test Adapter Hand held test unit MK II (ECU) Communications Lead Engine Timing Pin Piston Seal Assembly Tool Rubber Spacer Blocks ARV Extractor Torque Multiplier Drive Coupling Spanner Replacer- Bearing Cup Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Spanner Spanner Spool Clamp Mobile Oven 240V Static Oven 240V Static Oven Cut-out Knife ‘L’ Blades 2/4 Wheel Pressure Tester & Clamp Powershift Endfloat Checking Kit Battery Tester

Page No 7-3 7-2 7-2 7-2 4-1 4-1 4-2 4-1 4-2 4-3 4-2 4-2 5-1 7-1 7-1 7-3 7-2 7-3 5-3 5-3 8-2 6-4 4-3 6-2 7-2 7-1 7-1 7-1 7-1 7-1 7-1 7-1 7-1 6-2 6-2 6-2 4-1 4-1 4-1 4-2 4-2 7-2 7-4 5-1

1

892/00918

Setting Tool Kit. Contains the following: A Sleeve for M24 Pinion B

Adapter for M30 Pinion

C

fork (suitable for all axles)

7-5

The following setting tools must be purchased separately: 892/00945 A Sleeve for M30 Pinion 997/11100 2

997/11000

3

993/70111 -

B

Adapter for M24 Pinion Drive Head Setting Bracket

Breack-back Torque Wrench Solid spacer (see parts CD or microfiche for part numbers)

Ram Seal Protection Sleeves 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/01027

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 Piston Seal Assembly Tool

Powershift Endfloat Checking Kit (5 speed) 993/70104 892/01057 892/01056

6-4

7-5

Pillar, Input Shaft (5 speed) Pillar, 5th Speed Shaft Setting Body (5 speed)

The following parts are replacement items for kits and would normally be included in the kit numbers above.

Replacement item for kit no. 892/00180 892/00181 Replacement Boss

8-1

9803/3630

Issue 6*


Section 1



4-1

4- 1

Service Tools Section B - Body and Framework

S186240

S186270

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

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

'

S186250

992/12300 - 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).

S186280

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

S186260

992/12400 - 2 cartridge x 240V 992/12600 - 6 cartridge x 240V - 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

S186300

892/00842 - 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.

9803/3660

Issue 1


Section 1


4-2


4- 2

Service Tools (cont’d) Section B - Body and Framework (cont’d)

S186310

S186340

992/12800 - Cut-out Knife - used to remove broken glass.

892/00848 - Wire Starter - used to access braided cutting wire (below) through original polyurethane seal.

'

S186320 S186350

892/00846 - Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.

992/12801 (unit quantity = 5 off) 'L' Blades - 25mm (1in.) cut - replacement blades for cut-out knife (above).

S186330

892/00849 (approx 25m length) Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

S186360

892/00844 - Long Knife - used to give extended reach for normally inaccessible areas.

9803/3660

Issue 1


Section 1



4-3

4- 3

Service Tools (cont’d) Section B - Body and Framework (cont’d)

S186550 S186470

892/00847 - 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.

926/15500 (unit quantity = 500 off) Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.

892/00801

Clutch spanner for air conditioning compressor

S200940

892/00807

Front plate puller for air conditioning compressor

S200970

892/00802

Rotor puller set for air conditioning compressor

S200950

892/00808

Shaft protector for air conditioning compressor

S200980

892/00803

Rotor installer set for air conditioning compressor

S200960

9803/3660

Issue 1


Section 1



5-1

5-1

Service Tools Section C - Electrics

AVO Test Kit 1

892/00283

Tool Kit Case

2

892/00281

AVO Meter

3

892/00286

Surface Temperature Probe

4

892/00284

Venture Microtach Digital Tachometer

5

892/00282

100 amp Shunt - open type

6

892/00285

Hydraulic Temperature Probe

993/85700

Battery Tester

892/00905

Test Box for Safe Load Indicator and Load Moment Indicator

S188230

S239510

S244961

9803/3630

Issue 3


Section 1



5-2

5-2

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 72190005 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.)

S188380

9803/3630

Issue 2


Section 1



5-3

5-3

Service Tools (cont’d) Section C - Electrics

892/00943

Hand Held Test Unit MK II (ECU)

299920

892/00952

Communications Lead A314020

9803/3630

Issue 3


Section 1


6-1


6-1

Service Tools (cont'd) Section E - Hydraulics * Hydraulic Circuit Test Gauges and Connections 1 2 3 4 5

892/00279 892/00346 892/00347 892/00254 892/00280

Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-70 bar (0-1000 lbf/in2) Connector Hose Pressure Gauge 0-600 bar (0-9000 lbf/in2)

4

3 1,2,5

S188130 S188140

PressureTest 'T' Adaptors

Bonded Washers

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point

1406/0011 1406/0018 1406/0014 1406/0021 1406/0029

1 /4

in. BSP in. BSP 5 /8 in. BSP 3 /4 in. BSP 11/4 in. BSP 1 /2

Flow Test Equipment 892/00268 892/00269 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277

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

9803/3630

S188150

Issue 3*


Section 1



6-2

6-2

Service Tools (cont'd) Section E - Hydraulics

S193880

S193870

Female Cone Blanking Cap

Male Cone Blanking Cap

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

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

1 /4

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

S193900

S193890

T' Adapters

Female Connectors

892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B) 892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B) 892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B) 816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B) 892/00051 1 in. BSP (A) x 1/4 in. BSP (B)

892/00074 892/00075 892/00076 892/00077

3 /8

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

S192410

S193930

Hexagon Spanners for Ram Pistons and End Caps

Spool Clamps

992/09500 75mm A/F 992/09700 95mm A/F

892/00039 992/10100 992/02800

9803/3630

Spool Clamp Spool Clamp ARV Extractor

S188150

Issue 2


Section 1


6-3


6-3

Service Tools (cont'd) * Section E - Hydraulics * Male Adapters - BSP x BSP 1606/0003 3/8 in. x 1/4 in. 1604/0003 3/8 in. x 3/8 in. 892/00071 3/8 in. x 3/8 in. taper 1606/0004 1/2 in. x 1/4 in. 1606/0007 1/2 in. x 3/8 in. 1604/0004 1/2 in. x 1/2 in. 1606/0017 5/8 in. x 1/2 in. 1606/0008 3/4 in. x 3/8 in. 1606/0009 3/4 in. x 1/2 in. 1604/0006 3/4 in. x 3/4 in. 1606/0012 3/4 in. x 1 in. 1606/0014 3/4 in. x 11/4 in. 1606/0015 1 in. x 11/4 in.

S193860

*

* S193850

Pressure Test Adaptors 892/00255 1/4 in. BSP x Test Point 892/00256 3/8 in. BSP x Test Point 892/00257 1/2 in. BSP x Test Point 892/00258 5/8 in. BSP x Test Point 816/15118 3/4 in. BSP x Test Point 892/00259 1 in. BSP x Test Point 892/00260 1.1/4 in. BSP x Test Point 892/00261 5/8 in. UNF x Test Point

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

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1 1 /4 in M BSP x /4 in F BSP x Test Point Test Probe Gauge 0 - 400 bar (0-6000 lbf/in2)

S200141

*

Pressure Test Adapters 892/00964 892/00965

1/8 in BSP x Test Point 3/8 in BSP x Test Point 320380

9803/3630

Issue 3*


Section 1



6-4

6-4

7mm 11o 20mm

10mm

5mm R

m 3m

338410

Ram Seal Protection Sleeves 110mm 175mm 3o R 338500

892/01027

1.4

mm

Piston Seal Assembly Tool

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

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

161750X

308271

892/00948 892/00949

Charging Kit (without gauge) Gauge

161750Z

892/00334

Seal Fitting Tool

9803/3630

Issue 2*


Section 1



7-1

7-1

Service Tools (cont'd) * Section F - Transmission *

*

S188170

S188160

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

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

992/07603

*

Replacer- Bearing Cup

* S188200

S188190

892/00295 End Float Setting Tool

892/00179

*

Bearing Press

*

S197250

S188220

Bevel Box Heavy Duty Sockets 892/00912 46mm 892/00914 55mm 992/04800 Flange Spanner For locking pinion flange while nut is slackened or torque set

9803/3630

Issue 2*


Section 1


7-2


7-2

Service Tools (cont'd) * Section F - Transmission *

*

S197250

Heavy Duty Sockets 892/00817 17mm A/F x 3/4in square drive 892/00818 22mm A/F x 3/4in square drive

992/04000 Torque Multiplier

892/00819 15mm A/F x 1/2in square drive 892/00333 19mm A/F x 3/4in square drive

Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.

S197030

*

*

993/59300 2/4 Wheel Drive Clutch Pressure Test Adaptor & Clamp S196750 S162580

* Fixture for Syncro Shuttle & Powershift Gearbox removal & replacement. For details see MI 373/H, 358/E. 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. 892/00916 Clutch pack spring compressor S259320

9803/3630

Issue 2*


Section 1



7-3

7-3

Service Tools (cont'd) Section F - Transmission Alternative Pump Flow Test Adapters Flow Test Adaptor type C 1 449/03705 Adapter (side/central ports) 2 449/03702 Fitting Adapter 3 1604/0004 Adapter 4 1406/0018 Bonded Washer 5 2401/0222 O-ring

3 2

1

A314190

2

892/00237 Flow Test Adaptor type A (Complete) 1 892/00920 Flow Test Adapter 2 892/00301 Flow Test Adapter 3 892/00302 Flow Test Adapter

1 4 3

2

5

892/00812

4 5

1

313260 313260

Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling.

7 S196720

3 6

313250

Flow Test Adaptor type B 1 460/15708 Adapter (side ports) 2 460/15707 Banjo bolt 3 2401/0222 O-ring 4 2403/0110 O-ring 5 2403/0108 O-ring 6 1604/0004 Adapter 7 1406/0018 Bonded Washer Tighten adapters to 56 Nm (41 lbf ft).

892/00915

Bevel box gear reaction block

9803/3630

S259340

Issue 1


Section 1



7-4

7-4

Service Tools (cont'd) Section F - Transmission (cont’d) 1

993/70100

Powershift Endfloat Checking Kit (includes items 2 to 13)

*2

892/01055

Base Plate

3

993/70160

Yoke Assy

4

993/70130

Mainshaft Adapter Assy

5

993/70104

Mainshaft Pillar

6

993/70106

Layshaft/Reverser Pillar

7

993/70120

Layshaft Setting Assy

10 8

9

1391/3305

Capscrew (M8 x 20)

10

826/01417

Setscrew (M10 x 30) Flanged

11

993/70111

Setting Wrench (this is not part of the kit)

Input Setting Assy

6

5

Reverser Setting Assy

13† 993/70150

11 3

12

993/70140

Input Shaft Pillar

7

4

8

12† 993/70112

1

6 13 2

9

A191642 A191642

† 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

A B

36 17 81.75 96.35

9

9803/3630

Issue 2*


Section 1



7-5

7-5

Service Tools (cont'd) Section F - Transmission (cont’d) Powershift Endfloat Checking Kit - 5 Speed Transmission Base plate 993/70101 used for the 4-speed transmission can be adapted for use with 5 speed transmission. Cut out the corner section A, drill and counterbore the two holes B as shown below. Measurements are in mm. The later base plate 892/01055 is suitable for both 4- and 5-speed transmissions. The following setting tools must be purchased to use the kit with 5-speed transmissions: 14 15 16

993/70104 892/01057 892/01056

Pillar, Input Shaft Pillar, 5th Speed Shaft Setting Body

215 31 14.34

15

19.24 61.28

A 14 13.60

16 B

8.5

10

20

15

A362630

Solid Spacer Setting Tools 1

2 3

892/00918

Setting Tool Kit. Contains the following: A Sleeve for M24 Pinion B Adapter for M30 Pinion C fork (suitable for all axles)

The following setting tools must be purchased separately: 892/00945 A Sleeve for M30 Pinion 997/11100 B Adapter for M24 Pinion 997/11000 Drive Head Setting Bracket 993/70111 Breack-back Torque Wrench Solid spacer (see parts CD or microfiche for part numbers)

9803/3630

A270851

Issue 2*


Section 1


8-1


8-1

Service Tools (cont'd) Section H - Steering

892/00180

Seal Fitting Tool for fitting ‘O’ ring and back-up ring to Orbitrol Unit

892/00181

Replacement Plastic Boss

S191750

Section K - Engine

892/00041

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

S192390

For details of all engine service tools refer to engine service manual.

9803/3630

Issue 4*


Section 1



8-2

8-2

Service Tools (cont'd) Section K - Engine

Details for the manufacture of a lifting beam have been made available. This lifting beam enables the complete engine, bevel box and transmission unit to be removed from the machine as a complete assembly. Refer to Technical Information Bulletin 5/160 for the material and dimensional details required to manufacture the beam safely. Limitations on Use This tool is designed specifically to lift the side mounted engine, bevel box and powershift transmission as a complete assembly. The tool is not to be used to lift the engine on its own, any other part of the machine or for any other lifting duty or use.

A296430

892/00956

Timing pin for fuel injection pumps on JCB Diesel Engines type AR and AK builds only.

A314530

9803/3630

Issue 2*


Section 1



9-1 *

9-1

Sealing and Retaining Compounds JCB Multi-Gasket

A medium strength sealant suitable for all sizes of gasket 4102/1212 flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB Threadlocker

For threads of 50 mm diameter upwards,

4101/0451

50 ml

4102/0551

50 ml

e.g. suction strainer. JCB Threadlocker

A high strength locking fluid for use with threaded

(High Strength)

components. Gasketing for all sizes of flange where the strength of the joint is important.

JCB Retainer (High Strength) 50 ml

For all retaining parts which are unlikely to be dismantled.

4101/0651

JCB Threadlocker and Sealer

A medium strength locking fluid for sealing and retaining 4101/0250 nuts, bolts, and screws up to 50 mm diameter, and 4101/0251 for hydraulic fittings up to 25 mm diameter.

10 ml 50 ml

JCB Threadlocker and Sealer

A high strength locking fluid for sealing and retaining

4101/0550

10 ml

(High Strength)

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

4101/0552

200 ml

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

50 ml

JCB Activator

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

4104/0251 4104/0253

Aerosol (1 ltr) Bottle (200 ml)

JCB Cleaner/Degreaser

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

4104/1557

Aerosol (400 ml)

Anti-Seize Paste

A compound used for assembly and prevention of parts seizure.

4003/0211

Direct Glazing Kit

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

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1203

250 g

† Black Primer 206J

For direct glazing

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass.

4102/0901

Plastic to Metal Bonder

To seal plastic to metal joints

4103/0955

9803/3630

Issue 2*


Section 2

www.WorkshopManuals.co.uk Care & Safety

i


i

Contents

Page No.

Safety Notices

1-1

General safety

2-1

Operating safety

2-2

Maintenance safety

2-4

Lubricants - Health and Safety

3-1

9803/3630

Issue 1


Section 2


1-1


1-1

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

! DANGER Denotes an extreme hazard exists. If proper precautions are not taken it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3

9803/3630

Issue 1


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.

As well as the warnings in this chapter, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for maintenance practices.

Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6

General Safety

! WARNING

Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary.

Clothing You can be injured if you do not wear 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-1-3-4

INT-1-3-6

! WARNING

! CAUTION

! WARNING

Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, ie. combustible vapours, gas or dust, without first consulting your JCB Distributor.

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

INT-2-1-14

Lightning Lightning can kill you. Do not use the machine if there is lightning in your area.

INT-1-3-5

! DANGER

5-1-1-2

! WARNING Raised Boom A raised boom can fall or be lowered accidentally. Do not walk under a raised boom which is not fitted with a safety strut, or you could be injured. 5-1-1-1

! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure the lifting equipment is strong enough for the job. INT-1-3-7

9803/3630

Issue 1


Section 2


2-2


2-2

Operating Safety ! WARNING Practice You and others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. INT-2-1-1

! WARNING Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine. INT-2-1-2

! WARNING Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4

! WARNING ROPS/FOPS Structure The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9/3

! WARNING Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected. INT-2-1-5

! WARNING Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions. INT-2-2-9/1

! WARNING Engine The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6

! WARNING Passengers Passengers in or on the machine can cause accidents. The JCB Loadall is a one man machine. Do not carry passengers. INT-2-2-2

! WARNING Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. 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-2-1-7/1

! WARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air. INT-2-1-10

! WARNING 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

9803/3630

Issue 1


Section 2


2-3


2-3

! CAUTION

! WARNING

Work Site Work sites can be hazardous. Inspect the site before working on it. Check for potholes, weak ground, hidden rocks etc. Check for utilities (electric cables, gas and water pipes etc.) Mark the positions of underground cables and pipes. Make sure you have enough clearance beneath overhead cables and structures. See Working With the Loadall (OPERATION section) for more information about the danger of electrical cables.

Parking An incorrectly parked machine can move without an operator. Follow the instructions in this handbook to park the machine correctly.

5-1-3-1/1

! DANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-2-10

! WARNING Safe Working Loads Overloading the machine can damage it and make it unstable. Study the lifting and/or digging specifications in this handbook before using the attachments INT-2-2-11/1

! WARNING Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is a danger of collapse. INT-2-2-5

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

INT-2-2-4

! WARNING Visibility Accidents can be caused by working in poor visibility. Keep windows clean and use your lights to improve visibility. Do not operate the machine if you can not see properly. INT-2-1-11

! WARNING Rollover Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, DO NOT TRY TO JUMP FROM THE CAB. STAY IN THE CAB, WITH YOUR SEAT BELT FASTENED. INT-2-1-12

! CAUTION Fork Spacing Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting. 5-1-4-2

! CAUTION One-Fork Lifting A load lifted on one fork can slip off. Never lift a load with one fork. 5-1-4-3

! CAUTION Unloading Never unload the forks by stopping the machine suddenly. Follow the procedures in this handbook for unloading. 5-1-4-4

INT-2-2-6

! WARNING Safety Barriers Unguarded machines in public places can be dangerous. In public places, or when your visibility is reduced, place barriers around the work area to keep people away.

! CAUTION Uneven Ground Loads stacked on uneven ground can topple. Never stack loads on uneven ground. 5-1-4-5

INT-2-2-8

9803/3630

Issue 1


Section 2


2-4


2-4

! WARNING

! WARNING

Scaffolding Overloaded scaffolding can collapse. Never load scaffolding beyond the regulation capacity.

Forks/Turning The forks extend beyond the end of the boom. Make sure there is enough clearance for the forks when making turns.

5-1-4-6

5-1-5-4

! CAUTION

! DANGER

Overhead Clearance A raised boom can strike overhead objects. Always check for overhead clearance before before raising the boom.

Overhead Electrical Power Lines You can be electrocuted if you get your machine too close to live electrical power lines. Before starting work, find out if there are electrical power lines on the jobsite. If there are, contact the local electricity supplier and ask what safety precautions you must take. Also find out if there are any local laws and regulations concerned with work near electrical power lines.

5-1-5-1

! WARNING Boom/Travelling Operating the boom while travelling can cause accidents. You will not have total control of the machine. Never operate the boom while travelling. 5-1-5-2

! DANGER Forks/Working Platform Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform. 5-1-5-3

! CAUTION Regulations Obey all laws, work site and local regulations which affect you or your machine. INT-1-3-3

When you have found out what safety precautions, laws and regulations apply to the jobsite, make sure they are all obeyed. 5-1-5-6

! WARNING Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical 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

Maintenance Safety ! WARNING

! WARNING

Repairs Do not try to do repairs or any other type of maintenance work you do not understand. Get a Service Manual from your JCB distributor, or get the work done by a specialist engineer.

Boom Safety Strut A raised boom can drop suddenly and cause serious injury. Before working under a raised boom, fit the boom safety strut. See Boom Safety Strut (MAINTENANCE section). 5-1-5-7

INT-3-1-1

! 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 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 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

9803/3630

Issue 1


Section 2


2-5


2-5

! WARNING

! 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.

Counterweights Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them. INT-3-2-5

INT-3-1-3

! WARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual. 5-1-6-1

! WARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it. INT-3-2-8

! 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 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

! WARNING 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

! DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1/3

! WARNING Hot Coolant 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

! WARNING Tyres and Rims Over-inflated or over-heated tyres can explode. Follow the instructions in this handbook for inflating the tyres. Do not weld or cut rims. Get a tyre/wheel specialist to do any repair work. INT-3-2-6

! WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

! WARNING Battery 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 Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

9803/3630

Issue 1


Section 2



2-6

2-6

! CAUTION

! WARNING

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

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

INT-3-2-11

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

! 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 Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours. INT-3-1-6

! 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

When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

! WARNING Fluoroelastomeric Materials Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1

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

2

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

3

Thoroughly wash contaminated area with detergent and water.

4

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

! WARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9/1

DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1

9803/3630

Issue 1


Section 2 3-1



Lubricants - Health and Safety

3-1

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 engine 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 engine oil from skin: a Wash your skin thoroughly with soap and water. b

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

Using a nail brush will help.

c Use special hand cleansers to help clean dirty hands. d Never use petrol, diesel fuel, or paraffin for washing.

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.

e

Avoid skin contact with oil soaked clothing.

f

Don't keep oily rags in pockets.

g

Wash dirty clothing before re-use.

h

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 Eyes All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

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

Handling

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

New Oil

Skin

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

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

Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1

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

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 extinguishers. Do not use water. Fire-fighters should use self-contained breathing apparatus.

9803/3630

Issue 1




www.maskinisten.net

Section 3

www.WorkshopManuals.co.uk Routine Maintenance

i


i

Contents

Lubricants and Capacities - New Engines - Lubrication Charts - Type AA and AB Engines - Type AR, AK and AM Engines *

Page No.

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

Machine Safety

2-1

Working With the Boom Raised

2-1

Service Schedules

3-1

Grease - 50 Hours 530, 540 Machines 535 Machines - 500 Hours

4-1 4-2 4-3

Oiling

5-1

Tyre Inflation

6-1

Engine Air Filter - Changing the Elements

7-1

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

8-1 8-1

Engine Cover - Opening/Closing the Cover

8-2

Engine Cooling System - Checking the Coolant Level - Coolant Mixtures - Changing the Coolant

9-1 9-1 9-2

Cab Heater Filter - Cleaning

10 - 1

Fuel System - Fuel Types - Filling the Tank - Draining the Filter - Changing the Filter Element - Draining the Sediment Bowl - Cleaning the Sediment Bowl - Priming the System

11 - 1 11 - 2 11 - 3 11 - 3 11 - 4 11 - 4 11 - 5

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

12 - 1 12 - 2

9803/3630

Issue 6*


Section 3


ii


ii

Contents

Page No.

Axles - Checking the Axle Oil Level - Changing the Axle Oil

13 - 1 13 - 1

Front and Rear Hubs - Checking/Filling the Hub Oil Levels - Oil Immersed Brakes - Changing the Hub Oil

14 - 1 14 - 1 14 - 1

Hydraulic System - Checking the Fluid Level - Changing the Pilot Filter Element - Changing the Filter Element - Cleaning the Suction Strainer

15 - 1 15 - 1 15 - 2 15 - 3

Hose Burst Protection Valves - Checking the Hose Burst Protection Valves

16 - 1

Battery - Warning Symbols - Safety Notices - First Aid - Checking the Electrolyte Level - Isolator

17 - 1 17 - 1 17 - 2 17 - 2 17 - 3

Alternator Drive Belt Tension

17 - 4

Air Conditioning Option - Adjusting the Air Conditioning Compressor Drive Belt - Cleaning the Air Conditioning Filter

18 - 1 18 - 1

Brakes - Checking the Foot Brake Fluid Level

19 - 1

Preparation for Use - Checking for Damage - Checking Seat Belt Condition and Security - Cleaning the Machine

20 - 1 20 - 1 20 - 2

9803/3630

Issue 4


Section 3


1-1

Lubricants & Capacities


1-1

New Engines 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. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended in the lubrication charts.

Lubrication Charts Lubrication charts are included on the following pages for all machine models. Note that there are some differences in specifications for machines operating in North America. Be sure you identify the machine and its lubricant requirements.

9803/3630

Issue 2


Section 3




1-2

1-2

* Type AA and AB Engines ITEM Litres

CAPACITY UK Gal US gal

Fuel Tank

125

27.5

Engine (Oil)

10

(2.2)

30

2.6

Engine (Coolant)

23

5.0

Axles Housing Hubs (x4)

21 23

4.6 5.0

18 2.0

3.9 0.4

Housing Hubs (x4)

5.5 6.0

4.6 0.48

112 121

Braking System

Grease Points (See Note 3)

Wear Pad Runways

3

0.7

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

JCB 15W/40 Multigrade -10 °C - 50 °C (14 °F to 122 °F) JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F) JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)

SAE15W/40 API CF4/SG

NORTH AMERICA JCB 15W/40 Multigrade 14 °F to 122 °F (-10 °C to 50 °C) 10W/30 Multigrade 5 °F to 86 °F (-15 °C to 30 °C) JCB 10W 0 °F to 32 °F (-18 °C to 0 °C)

NORTH AMERICA Permanent Antifreeze JCB Extreme Performance Transmission Oil

NORTH AMERICA JCB Special Gear Oil JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)

24.6 26.6

530, 540 535

Diesel Oil (See Types of Fuel)

SAE10W/30, API CD/SE, SAE10W, API CD/SE SAE15W/40 API CF4/SG SAE10W/30, API CD/SE, SAE10W, API CD/SE ASTM D3306-74

ASTM D3306-74 JCB: 4000/2501

JCB High Performance Gear OIl API GL4

Hydraulic Tank (See Note 2) 530, 540 535

INTERNATIONAL SPECIFICATION

JCB Four Seasons Antifreeze and Summer Coolant 6.0

* Transmission (See Note 1)

FLUID/LUBRICANT

ESEN-M2C 86A/B ISO VG46

ISO VG32

29.5 32.0

NORTH AMERICA JCB Hydraulic oil

0.8

JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ISO VG15

JCB HP Grease

Lithium based

NORTH AMERICA JCB Moly EP 2 Grease

Lithium based No. 2 constituency

ISO VG46

JCB Waxoyl

Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres. Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

9803/3630

Issue 6*


Section 3




1-3

1-3

Type AR, AK & AM Engines ITEM Litres

CAPACITY UK Gal US gal

Fuel Tank

125

27.5

Engine (Oil)

10

(2.2)

30

23 23.5

5.0 5.2

INTERNATIONAL SPECIFICATION

Diesel Oil (See Types of Fuel)

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

JCB Super Multigrade 15W/40 CF4/SG, SAE15W/40 -10 °C to +50 °C (14 °F to 122 °F) JCB Super Multigrade 10W/30 CF4/SG, SAE10W/30 -15 °C to +40 °C (5 °F to 104 °F)

2.6

Engine (Coolant) AR & AK Engine: AM Engine:

FLUID/LUBRICANT

6.0 6.2

NORTH AMERICA JCB 15W/40 Engine Oil CF4/SG, SAE15W/40 14 °F to 122 °F (-10 °C to +50 °C) JCB Engine Oil 10W CF4/SG, SAE10W -4 °F to +50 °F (-20 °C to +10 °C) JCB Four Seasons Antifreeze and Summer Coolant NORTH AMERICA Permanent Antifreeze

* Transmission (See Note 1) 530FS Plus only 540FS Plus Axles Housing Hubs (x4)

21 23 17 19

4.6 5.0 3.7 4.2

18 2.0

3.9 0.4

Housing Hubs (x4)

5.5 6.0 4.5 5.0

4.6 0.48

112 121

Braking System

Grease Points (See Note 3)

Wear Pad Runways

3

0.7

NORTH AMERICA JCB Special Gear Oil

JCB High Performance Hydraulic Oil (Above 38 °C, 100 °F) JCB Special Hydraulic Fluid (Below 38 °C, 100 °F)

24.6 26.6

530, 540 535

ASTM D3306-74

JCB: 4000/2501

JCB High Performance Gear Oil API GL4

Hydraulic Tank (See Note 2) 530, 540 535

JCB Extreme Performance Transmission oil

ASTM D3306-74

ESEN-M2C 86A/B

ISO VG46

ISO VG32

29.5 32.0

NORTH AMERICA JCB Hydraulic oil

0.8

JCB Light Hydraulic Fluid DO NOT USE ORDINARY BRAKE FLUID

ISO VG15

JCB HP Grease

Lithium based

NORTH AMERICA JCB Moly EP 2 Grease

Lithium based No. 2 constituency

ISO VG46

JCB Waxoyl

Note 1: Wet fill capacity, eg. at fluid change 21 litres, dry fill capacity eg. after rebuild 23 litres. Note 2: This is a tank capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Note 3: If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

9803/3630

Issue 6*


Section 3



2-1

2-1

The machine must be made safe before carrying out any servicing.

Working with Boom Raised Fitting Safety Strut

Machine Safety

Carry out General Safety and the following procedure: Read Section 2, Care and Safety. Position the machine on firm level ground. Apply the parking brake. Chock both sides of all four wheels.

! WARNING You could be killed or injured if the boom drops while you are working under it. Install the safety strut as instructed below before doing any maintenance work with the boom raised. 5-3-1-2

Make sure the forward/reverse lever is in the neutral position. Fully retract the boom and lower to the ground. Switch OFF the engine and remove the starter key. Operate the controls to vent residual pressure. Release the hydraulic tank filler cap to release residual tank pressure. When welding electrically disconnect the alternator.

Fully retract the boom (unless it needs to be extended for maintenance). Raise the boom just far enough to install the strut. Make sure the parking brake is engaged and the transmission is in neutral. Switch OFF the engine and remove the starter key.

! CAUTION You will have to climb onto the machine to fit or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine. 5-3-1-11

! WARNING You could be killed or injured if the boom is lowered while you are under it. Keep people away from the machine while you fit the strut. 5-3-1-3

A

Remove the strut from its stowage position A. Place the strut around the ram piston rod as shown. Fix it in place with strap B. The strap fitted to the safety strut must be in a serviceable condition, if not fit a new strap. A343230 A343230

To prevent any chance of the boom creeping down and trapping your fingers, the boom should be lowered onto the strut. Note: Lower the boom carefully, to prevent possible damage to the strut. Stop as soon as the weight of the boom is on the strut.

B

S263560

9803/3630

Issue 4


Section 3



2-2

2-2

Working with Boom Raised (continued) Remove Safety Strut Start the engine and raise the boom to take the weight off of the strut.

B

Stop the engine. Make sure the parking brake is engaged and the transmission is in neutral. Remove the starter key.

! CAUTION You will have to climb onto the machine to install or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine. 5-3-1-11

S263560

! WARNING You could be killed or injured if the boom is lowered while you are under it. Keep people away from the machine while you remove the safety strut.

*

5-3-1-10

Undo the strap B, then remove the strut. Place the strut in its stowage position A.

A

A343230 A343230

9803/3630

Issue 2*


Section 3



Service Schedules

3-1

3-1

Pre-start Cold Checks Service Points and Fluid Levels

Operation

ENGINE Engine Air Filter Pre-cleaner Clean Oil Level and Condition Check Oil and Filter (1) Change Air Cleaner Dust Valve Clean Air Cleaner Outer Element Change Air Cleaner Inner Element Change Fuel System For Leaks and Contamination Check Fuel Filter Drain Fuel Filter Change Coolant Level Check Coolant Level and Antifreeze Strength Check Fuel Sedimenter Drain and Clean Fan Belt Tension/Condition Check Valve Clearances (AA - AC codes) *Check and Adjust Valve Clearances (AJ - AS codes) *Check and Adjust Engine Mount Security Check Rain Cap/Pre-cleaner installed (if fitted) Check Radiator Clean TRANSMISSION AND AXLES Transmission Oil Level Transmission Oil Transmission Oil Filter Axle(s) Oil Level Axle(s) Oil Hub Oil Level Hub Oil Drive Shafts and Universal Joints Axle Pivots and Linkages Axle Breather(s) Tyre Pressures/Condition Hub Wheel Bearings Transmission Strainer Wheel Nut Security Wheel Alignment Trunnion bearings Steering Stops (if fitted) Transmission Mount Security Axle Mount Security

Check (2) Change Change Check Change Check (3) Change Security/Grease Grease Check Check Check Clean Check Check *Check/Adjust Security Check Check

Daily 10 Hr

Weekly 50 Hr

Initial 100 Hr

z

z

z

z

z

6 Monthly Yearly 2 Yearly 500 1000 2000 Hr Hr Hr

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

z z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

(1)

In arduous conditions (eg. refuse re-handling, waste paper reclamation etc.) change the oil and filter every 250 Hours or three months (whichever comes first).

(2)

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

(3)

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

Note: Jobs which should be done by a specialist are shown by *. First 100 hrs service to be completed by JCB Distributor.

9803/3630

Issue 4*


Section 3



Service Schedules

3-2

3-2 Pre-start Cold Checks Service Points and Fluid Levels

Operation

HYDRAULICS Oil Level Oil System for Leaks Oil Filter Oil Strainers Pilot Filter

Check Sample/Change Check Change Clean Change

BRAKES Brake system Fluid

Check Level Change

ELECTRICS Battery Terminals for Condition and Tightness Wiring for Chafing

10 Hr

50 Hr

100 Hr

500 Hr

1000 Hr

2000 Hr

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

z

z

z

z

z

Check Check

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

* BODY AND FRAMEWORK Machine Generally All Pivot Pins All Hinges Wear Pad Runways Inner Boom Hoses Boom Wear Pad Clearance Control Lever Linkages Windscreen Washer Fluid Level Cab Heater Filter Fire Extinguisher Wing Mirror Condition and Security

Clean Grease Lubricate Waxoyl Grease Check/Adjust Replace if required Lubricate Check Clean Check Check

Functional Test and Final Inspection

Operation

ENGINE Idle Speed Torque Converter Stall Speed Max No Load Speed Throttle System and Control Cable Exhaust Smoke Exhaust System Security Air Inlet System Security Engine for Vibration and Noise

Check and Adjust Check Check Check/Adjust Check Check Check Check

TRANSMISSION AND AXLES Steer Operation Phasing Torque Converter Mainline Pressure Dump Switch Operation 2WD/4WD Selection (if fitted) Forward/Reverse/Gear Selection/Operation Neutral Start Operation Clutch Pack Pressures

Check Check Check Check Check Check Check

z

z z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

Daily 10 Hr

Weekly 50 Hr

Initial 100 Hr

z

z


z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

9803/3630

Issue 4*


Section 3



Service Schedules

3-3

3-3

Functional Test and Final Inspection

Operation

HYDRAULICS Operation of All Services Check Hose Burst Check Valves Check MRV Pressure at Max rpm Check and Adjust ARV Pressure at 750 rpm Check and Adjust Steer Circuit MRV Pressure Check and Adjust Fan Motor Speed Check and Adjust Attachment Operation Check Piston Rods and Chrome Check * Boom Extension/Phasing (3 Stage Boom) 535 machines Check Parallel Lift/Lower Check Stabiliser Leg and Sway Cut-Out (if fitted) Check BRAKES Foot Brake Operation Parking Brake

Check Check and Adjust

ELECTRICS Starter Motor Check Alternator Check Output All Electrical Equipment Operation (e.g. warning lights, beacons, alarms, horn, wipers etc) Check * Safe Load Indicator/Load Moment Indicator Check * Safe Load Indicator/Load Moment Indicator Calibrate Stabiliser Indicators Check BODYWORK AND CAB Inclinometer (if fitted) Check Glazing for Correct Fit /Leaks Check Seat/Seat Belts Check Air Conditioning (if fitted) Check Forks Fit and Check Security Machine Generally for Damage, Leaks & Wear Check

Daily 10 Hr

Weekly 50 Hr

Initial 100 Hr


z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

z

9803/3630

Issue 4*


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Grease Every 50 Hours

4-1 * 530,


4-1

540 Machines

56

3

1

2

9

4

78

°

0!

‡

¾

@ ›

½

£

‹

)

¼

*

%$^& (

9803/3630

S266510

Issue 2*


Section 3


4-2 * 535


4-2

Machines

*

1

* & ^

( %

2

)

$

3 @

£

9

8

4

!

0 9803/3630

5 6 7 345770

Issue 3*


Section 3


4 - 2A


Grease Every 50 Hours

4 - 2A

533 Machines Grease as shown for 535 plus the following (on both sides):

21 22

9803/3630

416030

Issue 1




www.maskinisten.net

Section 3


4-3

See Greasing (50 Hours) for general information on greasing. All 500 hour greasing operations must be carried out at 50 hour intervals if JCB MPL Grease is used. All 50 hour greasing operations must be carried out at 10 hour intervals if JCB MPL Grease is used. Note: When carrying out Greasing (50 hours) on the Rear Axle Trunnion Bearings (22, 23) an extra grease point may be found.


4-3

Extend the boom fully. Spray Waxoyl evenly over the surfaces A and B as shown. Allow 2-3 hours drying time before retracting the boom.

! CAUTION Waxoyl contains turpentine substitute, which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area. 5-3-1-9

A

A A

1

2

B

4

3

A335720 A335720

S263620

530, 540 Machines

A A

A A B

A343900 A343900

533, 535 Machines

* 9803/3630

Issue 3*


Section 3


5-1


5-1

Oiling The following points should be lightly oiled with engine oil at the periods stated in the Service Schedules: 1

Lightly oil all hinges.

2

Oil the clevis at the bottom of each control lever.

S267971

9803/3630

Issue 1


Section 3



6-1

6-1

! WARNING Over-inflated or overheated tyres can explode. Do not cut or weld the rims. Get a tyre/wheel specialist to do any repair work.

4

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.

5-3-2-4

Tyre Inflation These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job. 1

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

2

Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 lbf/in 2 ) above the recommended tyre pressure. See the chart Section F - Transmission for recommended tyres and pressures for your machine. (The tyre pressures are also given on the flip chart mounted in the cab and in the Specifications Section of the Operator Handbook).

Inflate the tyre to the recommended pressure. Do not over-inflate. Checking Roadwheel Nut Tightness On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. * Every day, before starting work, check that the wheel nuts are tight. If wheelnut torque indicators A are fitted, check each day that they have not moved. If wheelnut torque indicators are not fitted, check that the torques are correct as shown in the table below. Front Nm 680

Use an air hose fitted with a self-locking air chuck and remote shut-off valve. 3

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.

Rear lbf ft 500

Nm 680

lbf ft 500

! WARNING If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged. 2-3-2-8

A

416050

S089570

9803/3630

Issue 5*


Section 3



Engine Air Filter

7-1

7-1

Changing the Elements ! CAUTION

3

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.

4

Clean inside the canister H, pulsation ring L, cover C and dust valve J.

5

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.

6

Make sure that the wire is connected to the Air Filter Blocked switch.

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

Open the engine cover (see Engine Cover, this Section).

*

C H K

F

J 332260

D L

N

G

M N E

C

B M

9803/3630

J

S257910

Issue 4*


Section 3

www.WorkshopManuals.co.uk Routine Maintenance * Engine

8-1


Oil and Filter

8-1

Checking the Oil Level 1


*2


*3

Check that the oil level is between the two marks on the dipstick A. Add oil if necessary, through filler B. Use only the recommended oil (see Lubricants and Capacities, this Section). Make sure that the dipstick and filler cap are fully inserted and tightened.

Either remove the drain plug to allow oil to flow into the container or, if the drain plug kit is fitted, remove dust cap C and, with the free end of the clear plastic hose in the oil receptacle, screw on the drain coupling D and hose E. This automatically opens the valve, allowing the oil to flow into the container. Refit dust cap C hand tight only. 3

Change the filter: a

Unscrew the filter canister F. Remember that it will be full of oil.

b

Check that adapter G is secure.

! WARNING

c

Clean the filter head H.

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

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

Changing the Oil and Filter

2-3-3-2

1

Do steps 1 and 2 of ‘Checking the Oil Level’.

! WARNING You will have to get beneath the machine to drain the oil and change the filter. Make sure that the engine cannot be moved or started while you do these jobs.

*4

Fill the engine, to the upper mark on the dipstick, with new oil through the filler. See Lubricants and Capacities, this section, for recommended oil. Wipe off any spilt oil. Make sure the filler cap is correctly refitted.

5

Start the engine. Check for leaks. When the engine has cooled, check the oil level.

5-3-2-3

*2

Place a container of suitable size beneath the engine.

B A

J F

E C

D

H G

259251 S263531

F S174300

9803/3630

Issue 2*


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Engine Cover

8-2


8-2

Opening/Closing the Cover Access to the engine is by opening the cover.

! WARNING The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6

1


2

Unlock and release catch A. Allow the cover to raise on its gas strut. Keep hold of the cover while it rises.

3

Pull the cover down and engage catch A. We recommend you lock the engine cover

A

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

S263500

5-3-1-12/1

9803/3630

Issue 1


Section 3


9-1

* Engine Cooling System

! WARNING

9-1

Coolant Mixtures

The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9/1

Checking the Coolant Level 1


*2


3

Check the coolant level in the expansion bottle is between the MIN and MAX marks.

Note: If the level in the expansion bottle is low, then continue with steps 4 to 6. 4


Top-up the expansion bottle, through the filler cap A. The level should be between the MIN and MAX marks.

Note: Check the quality of the antifreeze mixture every year before the cold weather starts. Change it every two years. 5

Refit the filler cap, make sure it is tight.

6

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

To prevent the coolant freezing in cold conditions antifreeze must be added. JCB Antifreeze will give protection down to the temperatures shown in the table. Antifreeze Solution

Starts to freeze at

55%

-36 0C (-33 0F)

Never use less than 50% solution otherwise there will not be enough corrosion protection. Never use more than 60% solution otherwise the cooling system may be damaged. Leave the antifreeze in all year round as it gives protection against corrosion. Check the strength of the antifreeze solution at least once a year, preferably at the start of the cold period. Always renew the antifreeze every two years. A 50% antifreeze mixture should be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant's boiling point. Note: In climates where antifreeze is not necessary, a reputable corrosion inhibitor must be used. Renew the mixture every 6 months.

! WARNING Antifreeze can be harmful. Obey the manufacturer's instruction when handling neat or diluted antifreeze. 7-3-4-4

A

S263531

9803/3630

Issue 3*


Section 3



* Engine Cooling System

9-2

9-2

Changing the Coolant ! WARNING The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9/1

1

*2 3


7

Fill the system, use the necessary mix of clean, soft water and antifreeze. See Coolant Mixtures in this section.

8

Refit the filler cap, make sure the cap A is tight.

9

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

10

Top-up the expansion bottle, through the filler cap A. The bottle should be 1/3 full.

Open the engine cover (see Engine Cover, this Section). Carefully loosen filler cap A.

! CAUTION Keep your face away from the hose while disconnecting it. 5-3-3-1

4

Disconnect hose B and let the coolant drain out.

5

Flush the system, if necessary. Use clean water.

6

Refit radiator hose B.

A

B 9803/3630

S263531

Issue 3*


Section 3


10 - 1


10 - 1

Cleaning the Cab Heater Filter ! CAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

1

Park the machine on level ground. Engage the parking brake. Remove the starter key.

2

Carefully extract the filter A from its housing.

3

Knock loose dust off the filter. Wash the filter in clean water. Allow to dry.

Note: Do not squeeze the filter to dry it. Shake off the bulk of the water, then let the rest drain off. If the filter was clogged, clean it more often. 4

Carefully replace the filter into its housing.

A

S195410

9803/3630

Issue 1


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Fuel System

11 - 1


11 - 1

Types of Fuel

Fuel Standards

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

Consult your fuel supplier about the suitability of any fuel you are unsure of. Low Temperature Fuels

Cetane Number: Viscosity: Density: lb/pint) Sulphur: Distillation:

45(minimum) 2.5/4.5 centistokes at 40 °C (104 °F) 0.835/0.855 kg/litre (0.872/0.904 0.5% of mass (maximum) 85% at 350 °C(662 °F)

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

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.

Petrol

! WARNING Do not use petrol in this machine. Do not mix petrol with the diesel fuel. In storage tanks the petrol could rise to the top and form flammable vapours. INT-3-1-6

Density

Advice

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

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

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.

! 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

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

* 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.

9803/3630

Issue 3*


Section 3


11 - 2 *

*

Fuel System


11 - 2

Filling the Tank At the end of every working day, remove cap A and fill the tank with the correct type of fuel. This will prevent overnight condensation from developing in the fuel. We recommend that you lock the fuel cap to prevent theft and tampering.

! 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

A

S263590

9803/3630

Issue 3*


Section 3

www.WorkshopManuals.co.uk Routine Maintenance *

11 - 3

Fuel System


11 - 3

Draining the Filter

Changing the Filter Element

1


1

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.

2

Open the engine cover. 2

3

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

To assist with bleeding fill the filter element with fuel before fitting. Install filter element A, hand tight only. Check for leaks.

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.

! CAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the system.

2-3-3-11

2-3-3-11

A

B

S218870

9803/3630

Issue 3*


Section 3



Fuel System

11 - 4

11 - 4

Draining the Sediment Bowl

Cleaning the Sediment Bowl

1


1


2

Open the engine cover.

2


3

Look in the bowl M. If it contains sediment, do Steps 4 to 10, of Cleaning the Sediment Bowl. If there is water but no sediment, drain off the water by opening tap N.

3

Look in the bowl M. If it contains sediment, do Steps 4 to 10. If there is water but no sediment, drain off the water by opening tap N.

4

Disconnect the battery.

5

Clamp the fuel inlet hose O to prevent loss of fuel.

6

Support the bowl M; unscrew bolt P. Remove the bowl and element X.

7

Wash the bowl and element, use clean fuel.

8

Check the fuel Strainer (if fitted) is not blocked. See Fuel Strainer (Section B).

9

Refit the bowl and element, make sure gaskets are seated correctly. Remove the clamp from fuel inlet hose O.

10

Prime the system. See Priming the System.

! CAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the system. 2-3-3-7

O

P

M N X M S275110

9803/3630

N

S275120

Issue 4


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Fuel System

11 - 5


11 - 5

Priming the System * Machines with Type AA or AB Engines Air in the fuel system could cause misfiring or failure to start. Air will enter the fuel system if any part of the system has been drained or disconnected.

! CAUTION Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the system as detailed below. 2-3-3-7

1


2


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

A

2-3-3-2

3

Prime the fuel system. Operate the fuel lift pump priming lever A slowly, for approximately two minutes.

Note: If no fuel is moved when the fuel lift pump priming lever A 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. 4

S238480

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.

* Machines with Type AR, AK or AM Engines These engines are self priming. If just the sedimenter bowl is empty, turn the engine with the starter and the engine will self prime. If the sedimenter bowl, fuel pipes and fuel filter are empty, turn the engine with the starter for 30 seconds. Wait 60 seconds. Repeat this procedure three or four times and the engine will self prime. Note: Filling the filter element bowl with fuel will greatly reduce the time taken to prime the engine.

9803/3630

Issue 4*


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Transmission

12 - 1


12 - 1

Checking the Oil Level 1

Stop the engine and remove the starter key. Check the oil is above the minimum mark on dipstick A. Use only the recommended oil.

2

Start and run the engine slowly for a period of five minutes. This allows the oil to fill the filter, pump, torque converter, oil cooler and hoses.

3

Stop the engine, wait one minute. Recheck the oil level and fill to maximum mark on the dipstick.

A

S263531

9803/3630

Issue 6


Section 3


12 - 2


12 - 2

Changing the Oil and Filter The transmission oil should be drained through the orifice for the suction strainer. This will flush out any particles which fall off the strainer during its removal. 1

Park the machine on level ground. Make sure the parking brake is engaged. Fully retract the boom and lower to the ground. Stop the engine. Remove the starter key. Isolate the battery, see Battery Isolator (Maintenance section), to make sure the engine cannot be started.

! WARNING You will have to get beneath the machine to drain the oil and change the filter. Make sure that the engine cannot be moved or started while you do these jobs.

F E

5-3-2-3

2

Place a container of suitable size beneath the machine.

! CAUTION

S275150

D

When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer. 2-3-4-1

*3

Remove bolts D. Pull out the strainer E and its gasket F.

4

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

5

Fit the strainer and a new gasket F. Apply Threadlocker and Sealer to bolts D before fitting and tightening them.

9803/3630

Issue 5*


Section 3


12 - 3


12 - 3

Changing the Oil and Filter (continued) 6

Renew the filter: refer to the illustration which shows the filter installation on your machine. a Unscrew and remove the filter B. b On the new filter, smear seal C with transmission oil. c Screw the new filter in place until it just contacts the filter head, screw in a further 3/4 of a turn.

7

Fill the system with new oil through the dipstick/filler. See the chart at the end of MAINTENANCE section for recommended oil.

B C

C

B

S275140 A372830

9803/3630

Issue 2*




www.maskinisten.net

Section 3



13 - 1

13 - 1

* Axles

Checking the Axle Oil Level

Changing the Axle Oil

1


1


2

Clean the area around the fill/level plug A, and remove the plug. Oil should be level with the bottom of the hole. Add recommended oil if necessary (See Lubricants and Capacities in this section) Clean the plug before refitting.

2

Drain the oil: a Place a container of suitable size beneath plug B.

! CAUTION Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

b Remove plug B and its washer. Allow the oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed.) c Fit plug B and its washer. 3

Fill with recommended oil through fill/level hole A (See Lubricants and Capacities in this section). Clean the plug before refitting it. Tighten to 79 Nm (60 lbf ft).

A

A

B

B S263610 S263600

9803/3630

Issue 3*


Section 3


14 - 1


14 - 1

Front and Rear Hubs Checking the Hub Oil Levels

Changing the Hub Oil

Hubs must be checked separately.

1

Park the machine on level ground, with plug C at the bottom as shown. Engage the parking brake. Lower the forks to the ground. Stop the engine. Remove the starter key.

2

Drain the oil:

1

2

Park the machine on level ground with the OIL LEVEL mark A horizontal as shown. Engage the parking brake. Lower the forks to the ground. Stop the engine. Remove the starter key. Clean the area around the front plug B. Remove the plug. Oil should be level with the bottom of the hole. If necessary add oil (see Lubricants & Capacities in this * section). Clean the plug before refitting it. Torque tighten drain/fill plug to 35-40Nm (26-30 lbf ft).

a Place a container of suitable size beneath plug C. (see Lubricants & Capacities in this section).

! CAUTION

Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug. 2-3-4-2

Oil Immersed Brakes b Remove plug C. Allow the oil to drain out. The drain plug is magnetic. Wipe it clean. (Metallic particles should be carefully removed).

The axle oil is used to lubricate the brake components, and to cool the brake plates. It is important that the oil is changed regularly as specified in the service schedule - the lubricating properties of the oil will reduce as a result of brake wear.

*3 4

Fill with new oil, see Checking the Hub Oil Levels. Refit plug C and its seal. Torque tighten drain/fill plug to 35-40Nm (26-30 lbf ft).

B

OIL LEVEL

A

OIL LEVEL

C

A238490

9803/3630

Issue 5*


Section 3



15 - 1

15 - 1 *

Hydraulic System ! 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

Changing the Pilot Filter Element (Electrically operated spools only) 1

Park the machine on level ground and lower the boom to the ground. Engage the parking brake.

2

With the engine stopped, turn the starter switch to ON.

3

Operate the auxiliary switch to vent residual pressure.

4

Turn the starter switch to OFF, remove the starter key

Checking the Fluid Level 1

2

and battery isolator key.

Park the machine on level ground. Retract the boom. Set the forks on the ground. Stop the engine. Remove the starter key.

5

Remove the cover F.

6

Unscrew filter bowl G. The bowl should be hand tight, if necessary use a spanner on flats H.

Open the rear cover.

! CAUTION

7

Remove element J, wash the bowl, use clean fuel.

Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck.

8

Fit new element J. Screw bowl G in place, hand tight only.

9

Refit cover F.

5-3-4-8

3

Slowly remove filler cap A to allow system to vent fully and prevent oil being forced out of the filler neck. The fluid level should be between the two marks on dipstick B. If necessary, add recommended fluid through the filler. Refer to Lubricants & Capacities in this section.

! CAUTION Do not run the engine with the hydraulic tank filler cap removed. 5-3-4-1

F

A G

B

H A343240

J

S266710

9803/3630

Issue 4*


Section 3


15 - 2


15 - 2

Hydraulic System (continued) * Changing

the Filter Element

Park the machine on level ground. Make sure the parking brake is engaged. Fully retract the boom and lower to the ground. Stop the engine. Remove the starter key. Isolate the battery to make sure the engine cannot be started.

! CAUTION Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8

Operate the controls and then slowly remove the tank cap to vent residual pressure.

! CAUTION

Ensure that dirt etc. does not enter the hydraulic system during this job. 5-3-4-4

Canister Filter 1

5

Add hydraulic fluid, see Lubricants & Capacities in this section.

! 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

6

Check for leaks: a Make sure the filler cap is replaced, then run the engine for a few minutes. b Make the machine safe. c Check for leaks at the filter.

Clean the area around the filter body.

! WARNING You will have to get beneath the machine to drain the oil and change the filter. Make sure that the engine cannot be moved or started while you do these jobs. 5-3-2-3

2

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

3

From under the machine, unscrew and remove the element A. The element will contain hydraulic fluid; keep your face clear of spilling fluid.

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

A

2-3-4-1

4

Fit the new element: a Clean the mating faces on the new element and filter holder. b Smear the seal B with hydraulic fluid.

B S275130

c Screw the new element in place, hand-tight only.

9803/3630

Issue 3*


Section 3



15 - 3

15 - 3

Hydraulic System (continued) *

Cleaning the Suction Strainer 1

Position the machine on firm level ground. Fully lower the boom, apply the parking brake, stop the engine and remove the starter key.

2

Operate the controls to vent residual pressure.

*

! CAUTION Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck.

A

5-3-4-8

3

Slowly remove the hydraulic tank filler cap A allowing the system to vent fully and prevent oil being forced out of the filler neck.

4

Allow the hydraulic oil to cool and then prepare to drain the tank. Note the oil capacity (see Lubricants & Capacities) and drain into a suitable container by

A343240

removing plug B.

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

*

2-3-4-2

5 *6

Undo bolts C and remove cover plate D and gasket E.

F

Using an 80mm A/F spanner, undo and remove the suction strainer F.

Cleaning *

*

1

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

E

Replacement Replacement is the reversal of the removal procedure. Fit a new sealing washer G.

G

Torque settings Item C

Nm 10.5

D

kgf m 1.1

lbf ft 8.0

9803/3630

A293890

B C

Issue 3*




www.maskinisten.net

Section 3


16 - 1


16 - 1

Hose Burst Protection Valves The hose burst protection valves 'lock' to prevent uncontrolled movement of the ram pistons if hydraulic pressure fails or a hose bursts. The check valves are mounted directly on the rams. Checking the Hose Burst Protection Valves

! WARNING Keep people clear of the machine while you do these checks. 5-3-4-2

Check each movement in turn. 1

Boom Lift Ram

2

a Start the engine. Make sure the parking brake is engaged and the transmission is in neutral. b Raise the boom to about 45°. c With the engine running at mid speed, operate the control lever to lower the boom. While the boom is moving, switch off the engine. Boom movement should slow as the engine slows and stop as the engine stops.

a Start the engine. Make sure the parking brake is engaged and the transmission is in neutral. b Raise the boom fully. Extend the boom fully. c With the engine running at mid speed, operate the control lever to retract the boom. While the boom is retracting, switch off the engine. Boom movement should slow as the engine slows and stop as the engine stops.

If the boom continues moving after the engine has stopped, the boom hose burst protection valve is faulty. Do not use the machine until the fault has been put right.

*

Boom Extension Ram

If the boom continues moving after the engine has stopped, the hose burst protection valve is faulty. Do not use the machine until the fault has been put right.

*

A335710 A335700

9803/3630

Issue 2*


Section 3


16 - 2


16 - 2

Hose Burst Protection Valves (continued) See previous page for general information on hose burst protection valves. 3

Carriage Tilt Ram a Pick up a load on the forks. (For example a pack of bricks or some hay bales.) Secure the load to the forks using straps or ropes. Tilt the carriage fully back. Make sure the parking brake is engaged and the transmission is in neutral. b Position the boom clear of the ground, just far enough to allow the carriage to be tilted forward. c With the engine running at mid speed, operate the control lever to tilt the carriage forward. While the carriage is moving, switch off the engine. Carriage movement should slow as the engine slows and stop as the engine stops.

If the carriage continues moving after the engine has stopped, the hose burst protection valve is faulty. Do not use the machine until the fault has been put right.

*

A335640

9803/3630

Issue 2*


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Battery

17 - 1


17 - 1

Battery ! CAUTION

Warning Symbols The following warning symbols may be found on the battery.

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

Symbol

Meaning

INT- 3- 1-14

Keep away from children.

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

! WARNING

INT-3-1-4 A289230

! DANGER Shield eyes.

A289260

Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1/3

! CAUTION No smoking, no naked flames, no sparks. A289280

Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12

Explosive Gas.

A289250

Battery acid.

! WARNING 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

A289240

Note operating instructions.

A289270

9803/3630

Issue 2


Section 3



Battery

17 - 2

! WARNING

17 - 2

Checking the Electrolyte Level

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, fit the positive (+) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.

Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditions (such as prolonged operation at tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below. 1

With key unlock and open the battery compartment cover B.

! WARNING Keep metal watch straps, and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If this happens you can get burned. 5-2-2-4

2

Disconnect and remove battery.

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

First Aid - Electrolyte Do the following if electrolyte:

2-3-4-6

GETS INTO YOUR EYES

3

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

4

Refit battery and lock the battery compartment.

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

C

S089660

B

9803/3630

S263581

Issue 3


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Battery

17 - 3


17 - 3

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

! CAUTION

B

A C

Except in an emergency, do not use the battery isolator to switch OFF the engine. Failure to comply may result in damage to the electrical circuits. INT-3-2-13

At the end of a working cycle or if the machine is being left unattended, provided the lights are not required, the battery must be isolated. Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switched on. 1

To isolate the battery turn the battery isolator key A in an anti-clockwise direction B and remove. Keep the key in a safe place and available for when the machine is next required.

2

To connect the battery insert the key A and turn in a clockwise direction C.

S263580

Note: The battery isolator position varies (this illustration is typical). Refer to the illustration applicable to your machine (see Machine Operator Handbook.

! CAUTION Before carrying out arc welding on the machine disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if the battery isolator is fitted. Make sure that the welding earth return path is kept as short as possible. This prevents high currents being induced in the machine chassis or wiring harnesses. If the machine is equipped with electronic control units (ECUs), then disconnect them before welding. Failure to disconnect the ECUs could result in irreparable damage to the electronic components. INT-3-1-15

9803/3630

Issue 3


Section 3



Alternator Drive Belt Tension

17 - 4

17 - 4

Adjusting the Alternator Drive Belt 1

Park the machine on level ground. Lower the boom to the ground. Engage the parking brake. Remove the starter key.

! WARNING

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

2


3

Undo the bolts E and remove the drive belt cover F.

4

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

5

Position the alternator so that there is 10 mm ( /8 in)

E

F

E

E

3

slack at point X. 6

Secure the alternator, tighten bolts C and D, then bolts A and B.

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

! WARNING You or others could be seriously injured by rotating parts if the alternator drive belt cover plate is not fitted. Always refit the cover plate before starting the engine. 5-3-4-5

7

A296370

A

B

Refit the drive belt cover F secure with bolts E.

Torque Settings Item D

Nm 60

Kgf m 6.0

lbf ft 44

C D

X

A296490

9803/3630

Issue 2


Section 3



18 - 1

18 - 1

Air Conditioning Option

Cleaning the Air Conditioning Filter In dusty conditions the filter will require cleaning/changing more often.

! WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system must be disconnected except by a qualified refrigeration engineer. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/1

! CAUTION The filter may be filled with dust. Wear goggles and a face mask when removing the filter. 2-3-3-6

Adjusting the Air Conditioning Compressor Drive Belt

1

Park the machine on level ground. Engage the parking brake. Raise the boom and fit the safety strut, as described in this section. Remove the starter key.

1

Park the machine on level ground. Lower the boom to the ground. Engage the parking brake. Remove the starter key.

2

Isolate the battery.

3

Remove cover plate D.

2

Isolate the battery.

4

Sponge type filter, knock loose dust off the filter. Wash the filter in clean water. Allow to dry.

3


4

Loosen bolts A, and B. Position the compressor so that there is 10 mm (3/8 in) slack at point C.

5

Tighten bolt A, then bolt B.

Note: Do not squeeze the filter to dry it. Shake off the bulk of the water, then let the rest drain off. If the filter was clogged, clean it more often. Paper type filter, fit a new filter. 5

Remove cover plate E, brush debris from the evaporator fins. Make sure loosened material is brushed out of the heater enclosure.

6

Refit cover plates D and E.

C D A B S278240

E S278140

9803/3630

Issue 1


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Brakes

19 - 1


19 - 1

Checking the Foot Brake Fluid Level ! WARNING Faulty brakes can kill. If you have to top up the brake reservoir frequently, get the brake system checked by your JCB distributor. Do not use the machine until the fault has been put right.

A

2-3-2-5/1

! WARNING Using incorrect brake fluid could damage the system. See the Fluids, Capacities and Lubricants chart in this publication for the correct fluid. The fluid can harm your skin. Wear gloves. Cover cuts and grazes. 2-3-2-6/2

The brake master cylinder is in the cab. 1

Check the fluid level The correct fluid level is marked on the reservoir. If necessary, add fluid as in step 2.

2

Add Fluid

S288500

Remove the reservoir cap A. DO NOT USE ORDINARY BRAKE FLUID. Carefully pour in the fluid until it reaches the FLUID LEVEL mark. Avoid spilling the fluid. Wipe up any spillage.

9803/3630

Issue 1


Section 3

www.WorkshopManuals.co.uk Routine Maintenance Preparation for Use

20 - 1


20 - 1

Checking for Damage Make sure all pivot pins are correctly in place and secured by their locking devices. Ensure that the steps and handrails are undamaged and secure. Check for broken or cracked window glass. Replace damaged items. Check all bucket teeth for damage and security. Check all lamp lenses for damage. Inspect the tyres for damage and penetration by sharp objects. Check that all safety decals are in place and undamaged. Fit new decals where necessary, see Safety Decals (Introduction, Owners Manual).

Checking Seat Belt Condition and Security ! WARNING Replace the seat belt with a new one it it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years regardless of condition. 2-3-1-8

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly. Check that the belt mounting bolts are undamaged, correctly fitted and tightened.

9803/3630

Issue 1


Section 3


20 - 2


20 - 2

Cleaning the Machine * Machines to Serial Number 784534 Clean the machine using water and/or steam. Avoid using neat detergent - always dilute detergents as per the manufacturer’s recommendations, otherwise damage to the paint finish may occur. Always grease the machine after pressure washing or steam cleaning. Note: Excessive power washing can damage seals and bearings. Do not direct high power water jets directly at oil seals or universal joints.

Clean both sides of radiator A, condenser F and guard D. When clean close and secure condenser assembly, refit and secure guard D. 2

Debris can collect under the boom B. Remove especially all combustible material.

3

Do not allow debris to accumulate around the engine, pay particular attention to the exhaust area C, remove all combustible material.

4

Do not allow debris to accumulate in the cavity at the end of the boom on 530 and 540 machines. Remove and clean away all debris that may have built up.

Pay particular attention to the following: 1

If the radiator tubes/fins get clogged the radiator will be less efficient. Brush off all debris from the cooler tubes and fins using a soft bristle brush. Make sure the loosened material is brushed out of the cooler enclosure. Open the engine cover and remove guard D (if fitted). Clean both sides of guard D (if fitted) and clean both sides of radiator A. On machines fitted with air conditioning, unclip and remove guard D. Release fastener E and hinge condenser assembly to the rear.

A

C

! WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Please inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. 5-3-1-12/2

D

B

F

E

9803/3630

Issue 3*


Section 3


20 - 3


20 - 3

Cleaning the Machine (continued) * Machines from Serial Number 784535 Clean the machine using water and/or steam. Avoid using neat detergent - always dilute detergents as per the manufacturer’s recommendations, otherwise damage to the paint finish may occur. Always grease the machine after pressure washing or steam cleaning. Note: Excessive power washing can damage seals and bearings. Do not direct high power water jets directly at oil seals or universal joints. Pay particular attention to the following: 1

2

Debris can collect under the boom D. Remove especially all combustible material.

3

Do not allow debris to accumulate around the engine, pay particular attention to the exhaust area E, remove all combustible material.

4

Do not allow debris to accumulate in the cavity F at the end of the boom on 530 and 540 machines. Remove and clean away all debris that may have built up around the tilt ram.

If the radiator tubes/fins get clogged the radiator will be less efficient. Brush off all debris from the cooler tubes and fins using a soft bristle brush. Make sure the loosened material is brushed out of the cooler enclosure. Open the engine cover to clean both sides of radiator A.

! WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Please inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. 5-3-1-12/2

On machines with air conditioning, release fastener B and hinge the condenser away from the radiator. Clean both sides of condenser C.

F D E

A B C

9803/3630

387280

Issue 1




www.maskinisten.net

Section A

www.WorkshopManuals.co.uk Optional Attachments

i

www.maskinisten.net Section A

i

Contents

Quick Release Couplings

Page No.

1-1

9803/3630

Issue 1


Section A 1-1

www.WorkshopManuals.co.uk Optional Attachments

www.maskinisten.net Section A

Quick Release Couplings

Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. The attachment pipework has two male couplings fitted on the loader arms and two on the backhoe. The attachment hoses have corresponding female couplings 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.

1-1

! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication. HYD 1-5

Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented, see Section E, Contents.

Connecting Quick Release Couplings 1

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

DO wipe the two faces of the coupling and make sure they are clean before connecting.

2

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

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

3

Make sure that the ball C in the female coupling is located in one of its slots.

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'.

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 slot D.

Quick Release Couplings - Do's & Don'ts

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 hoses.

2

Align 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.

E

C D

169490

980/3630

Issue 1


Section B

www.WorkshopManuals.co.uk Body & Framework

i

www.maskinisten.net Section B

i

Contents

Boom Shimming - Typical Method - Measurements - 530, 540 Machines * - 533-105, 535-95 Machines Boom Removal and Replacement - 530, 540 Machines *- 533-105, 535-95 Machines

Page No.

1-2 1-4 1-6

1-8 1 - 10

Cab - Removal and Replacement - Rivet Nuts - Direct Glazing

1 - 12 2-1 3-1

Fuel Tank - Removal and Replacement - Fuel Strainer

4-1 4-2

Accelerator Cable - Removal and Replacement - Adjustment

5-1 5-2

Air Conditioning - Technical Data - Safety Procedures - General Description - Refrigerant - Operation and Control - Service Ports - Leak Testing - Evaporator Removal - Thermostat Removal - Binary Pressure Switch - Service Checks - Cleaning the Condensor - Wiring Diagram - Fault Finding

7-1 7-2 7-3 7-5 8-1 8-2 8-2 8-3 8-4 8-5 9-1 9-2 9-3 10 - 1

9803/3630

Issue 6*


Section B

www.WorkshopManuals.co.uk Body and Framework

1-1


1-1

H

J

A G

259400

9803/3630

Issue 1


Section B



1-2

1-2

BOOM SHIMMING - TYPICAL METHOD * This procedure details a typical method for shimming a boom, for specific information see Boom Shimming Measurements.

Fit or remove shims H to obtain correct vertical clearance. Measure total thickness of shims under each pad.

Shims are fitted under the pads for adjustment of boom clearance. Partly worn pads may be shimmed to restore correct boom clearance.

Add or remove plain washers J under heads of wear pad bolts G to ensure correct thread engagement. Use machine tables to calculate the number of washers required.

On 2 stage machines shim inner boom to outer boom.

Refit shims and torque tighten bolts G, see machine tables.

On 3 stage machines shim intermediate boom to outer boom then repeat the procedure for inner to intermediate boom.

Front Side Wear Pads

Renew the wear pads when, or before they are worn down to depth of chamfer as shown at A.

Pull the boom to one side and measure the total side clearance F of boom which should be as specified in machine tables. Slacken side wear pad bolts G and shim as required. Divide number of shims equally each side to ensure that inner boom runs centrally within the outer boom.

Front Lower Wear Pads Raise boom slightly so that forks are just off the ground.

Measure total thickness of shims under each pad. * Measure distances between lower boom faces which should be as specified in machine tables (see Boom Shimming Measurements). If this dimension is below limits shims must be fitted under the lower wear pads to restore the dimension.

Add or remove plain washers J under heads of wear pad bolts G to ensure correct thread engagement. Use machine tables to calculate the number of washers required. Refit shims and torque tighten bolts G, see machine tables.

Rest the forks on the ground so that there is no weight on the lower wear pads. Remove lower wear pad bolts G and add shims H as required to restore dimension B, C or D see machine tables. Measure total thickness of shims under each pad. Add or remove plain washers J under heads of wear pad bolts G to ensure correct thread engagement. Use machine * tables to calculate the number of washers required. Refit shims and torque tighten bolts G, see machine tables in Boom Shimming - Measurements.

Rear Lower Wear Pads Rest forks on the ground then remove the boom rear cover. Measure distances between lower boom faces which should be as specified in machine tables. If this dimension is below limits shims must be fitted under the lower wear pads to restore the dimension. Raise boom slightly so that forks are just off the ground and place wedges under the inner boom Remove lower wear pad bolts and add shims as required to restore dimension.

Front Top Wear Pads Measure total thickness of shims under each pad. Raise the boom until the inner boom is resting on the lower wear pads. Measure total vertical clearance E which should be as specified in machine tables.

Add or remove plain washers under heads of wear pad bolts to ensure correct thread engagement. Use machine tables to calculate the number of washers required. Remove wedges, refit shims and torque tighten bolts, see machine tables. Rear Top Wear Pads As detailed for front top wear pads. Rear Side Wear Pads As detailed for front side wear pads.

9803/3630

Issue 2*


Section B


1-3


1-3

*

B

C A

S259410

9803/3630

Issue 3*



Section B


1-4 *

1-4

Boom Shimming - Measurements Number of plain washers to be fitted under bolt

530, 540 Machines The detail on this page gives the measurements relating to the machines listed above. For the shimming method, see Boom Shimming - Typical Method, this section. Make sure wear pads are fitted the correct way round to prevent fouling.

A

Maximum

Maximum

Gap (mm)

Gap (in)

37-41

1.45 to 1.60

3

0.12

Boom Front

1.5

0.06

Boom Rear

3

0.12

Boom Front

1.5

0.06

Boom Rear

B

C

Shim thickness

Number of washers

Front Top pads

0 to 3 mm 3.2 to 6 mm 6.2 to 8 mm

3 2 1

Front Bottom pads

0 mm 1.6 to 3 mm 3.2 to 8 mm

4 3 2

Rear Top pads

0 to 3 mm 3.2 to 6 mm 6.2 to 8 mm

2 1 0

Front Side pads

0 mm 1.6 to 3 mm 3.2 to 6 mm 6.2 to 8 mm

4 3 2 1

Rear Side pads

0 mm 3 mm 3.2 to 6 mm 6.2 to 8 mm

2 1 0

Torque setting 98 Nm (72 lbf ft, 10 kgf m)

9803/3630

Issue 3*


Section B



1-5

1-5

*

C

D E

D B

A

F

E

259420

9803/3630

Issue 2*



Section B


1-6

1-6

Boom Shimming - Measurements Number of plain washers to be fitted under bolt

* 533-105, 535-95 Machines The detail on this page gives the measurements relating to machines listed above. For the shimming method, see Boom Shimming - Typical Method, this section. Make sure wear pads are fitted the correct way round to prevent fouling.

Maximum

Maximum

Gap (mm)

Gap (in)

A

37-41

1.45 to 1.60

B

21-25

0.83-0.98

C

3

0.12

D

1.5

0.06

Intermediate to outer boom. Shim thickness

Number of washers

Front Top pads

0 mm 1.6 to 4.6 mm over 4.6 mm

3 1 0

Rear Top pads

0 mm 2 to 3 mm 4 to 6 mm 7 to 8 mm

4 3 2 1

Front Side pads

0 to 1.6 mm 3 to 5 mm 6 mm

5 4 3

Rear Side pads

0 mm 1.6 to 3.2 mm 3.6 to 6 mm

4 3 2

Bottom pads

0 mm 1.6 to 3.2 3.6 to 6.0

4 3 2

Note: The intermediate to outer boom, bottom right hand wear pad (shown at E) may vary, check the parts catalogue. Inner to intermediate boom. Shim thickness

Number of washers

Top pads Front

0 mm 2 to 3 mm 4 to 6 mm 7 to 8 mm

4 3 2 1

Top pads Rear

0 mm to 8 mm

0

Side pads Front

0 to 1.6 mm 3 to 5 mm 6 mm

5 4 3

Side pads Rear

0 mm 1.6 to 3.2 mm 3.6 to 6 mm

4 3 2

Bottom pads

0 mm 1.6 to 3.2 3.6 to 6.0

4 3 2

Note: Use dome headed Tuf-Lok bolts at E and F. Torque setting 98 Nm (72 lbf ft, 10 kgf m).

9803/3630

Issue 4*


Section B



1-7

1-7

E

B

A

F

G

H C J

D

291060

9803/3630

Issue 2


Section B



1-8 * Boom

1-8

Removal and Replacement

530, 540 Machines

! WARNING 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 the lifting equipment is strong enough for the job. INT-1-3-7

6

Loosen the filler cap to vent the hydraulic tank. Label the connections and disconnect hydraulic hoses at E.

7

Label the connections and disconnect extension ram hoses F and G.

* 8

Ensure the boom is fully supported. Note that there will be one of three types of main pivot pin for the boom. Type 1 is shown opposite. Types 2 & 3 are shown below.

! 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.

Type 1 Remove bolt H and withdraw the pivot pin. Types 2 & 3 Remove items 1 - 6, noting the quantity and arrangement of the spacers.

INT-3-1-11/1

! WARNING NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

* 9

Carefully lift the boom clear of the machine, checking for any remaining connections. Lower the boom onto suitable packing material.

Replacement

INT-3-3-7/1

Replacement is the reverse of the removal procedure. Removal Check the hydraulic oil level and refill if necessary. Note: The complete boom assembly has a mass of approximately 3,000kg (6,613lb). The lift ram has a mass of approximately 250kg (550lb). Support the ram at all times to prevent personal injury and damage to the machine and equipment. 1

Position the machine on firm level ground and apply the handbrake. Remove any boom attachments, including forks and fork bar.

2

Fully lower the boom. Open the rear access cover and disconnect the displacement ram by removing bolts A and withdrawing pivot pin B. Operate the carriage crowd control to retract the displacement ram.

3

Lower the boom onto a suitable support in the semiraised position to gain access to the lift ram rod end. Support the boom from above ready for removal. Use lifting shackles of suitable capacity fitted to the forward lifting points if the carriage is fitted, or the rear lifting points if the carriage is not attached.

4

Support the lift ram and disconnect the lift ram rod end by removing bolt C and withdraw pivot pin D. Operate the boom lower control to fully retract the ram. Lower the ram onto suitable packing material to protect the piston rod.

5

Switch off the engine and operate the controls to vent residual pressure.

Grease all pivot pins, see Service Schedules, Section 3. * For main pivot pins types 2 & 3, do the following: identify the position and quantity of all washers and spacers for the Loadall model, as shown below. Align the locking plate and fit spacer 2, large washer 3, washers 5 and bolt 4. Secure in place with washer 5 and nut 6. Tighten the bolt to 476 Nm (352 lbf ft).

540 4

530 4

9803/3630

347510

Issue 3*


Section B



1-9

1-9

E

Y A H J

B C

D

G F 345810

9803/3630

Issue 2*


Section B



1 - 10

1 - 10

Boom Removal and Replacement * 533-105, 535-95 Machines

! WARNING 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 the lifting equipment is strong enough for the job.

6

Remove bolt F and withdraw pivot pin G. Lower the displacement ram onto suitable packing material to protect the piston rod.

7

Label the connections and disconnect hydraulic hoses at E.

8

INT-1-3-7

! 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.

Ensure the boom is fully supported. Remove bolt H and withdraw pivot pin J. Carefully lift the boom clear of the machine, checking for any remaining connections. Lower the boom onto suitable packing material.

Replacement Replacement is the reverse of the removal procedure.

INT-3-1-11/1

Check the hydraulic oil level and refill if necessary.

! WARNING NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

Grease all pivot pins, see Service Schedules, Section 3.

INT-3-3-7/1

Removal Note: The complete boom assembly has a mass of approximately 2039 kg (4496 lb). The lift ram has a mass of approximately 111 kg (245 lb) and the displacement ram 31 kg (69 lb). Support the ram at all times to prevent personal injury and damage to the machine and equipment. 1

Position the machine on firm level ground and apply the handbrake. Remove any boom attachments.

2

Lower the boom onto a suitable support in the semiraised position to gain access to the lift ram rod end. Support the boom from above ready for removal. Use lifting shackles of suitable capacity fitted to the forward lifting points if the carriage is fitted, or the rear lifting points if the carriage is not attached.

3

Support the lift ram and disconnect the lift ram rod end by removing bolt A and withdraw pivot pin B. Operate the boom lower control to fully retract the ram. Lower the ram onto suitable packing material to protect the piston rod.

4

Switch off the engine and operate the controls to vent residual pressure.

5

Support the displacement ram. Loosen the filler cap to vent the hydraulic tank. Label the connections and disconnect the displacement ram hoses at C and D.

9803/3630

Issue 4*


Section B


1 - 11


1 - 11

343620

9803/3630

Issue 2


Section B



Cab

1 - 12

1 - 12

Removal and Replacement Removal

! WARNING Make the machine safe before getting underneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake engaged and the transmission is in neutral. Chock both sides of all four wheels.

Procedures for charging and discharging the system are not given in this manual as they require special equipment and training. If necessary use the services of a specialist refrigerant engineer (see Air Conditioning - this section).

5-3-2-1/1

Once the system has been discharged, disconnect hoses at the Thermostatic Expansion Valve (TEV) K.

Carry out Machine Safety procedures (see Working with the Boom Raised, Section 3).

11 P.

Unscrew and remove cab mounting bolts L, M, N and

1

Remove the battery cover and disconnect the battery.

12

Attach appropriate lifting equipment to the ROPS and FOPS cage.

2

Disconnect and cap all hydraulic hoses from steering unit, shown at A.

13

Carefully lift the cab from the machine, ensuring that all connections have been released and are clear of any obstruction. Cap off fuel tank filler neck S to prevent contamination.

3

Remove heater cover X if fitted. Undo the hose clips and disconnect heater hoses at points B.

*4

Disconnect engine accelerator cable C at engine (see Accelerator Cable, this section).

5

Ensure all wheels are chocked and release parking brake. Disconnect parking brake cable D.

6

Remove valve block control lever gaiter plate and push gaiters outside cab.

Replacement Replacement is a reversal of the removal procedure. Bleed the brakes in accordance with Brakes, Section G.

7

Disconnect cab electrical harness, shown at E.

8

Undo the fuel filler hose clip F. Loosen the fuel tank filter hose on fuel tank filler neck S so that the two separate at step 13.

Recharge air conditioning system (if fitted), see Air Conditioning - this section. Ensure all electrical and hydraulic services operate correctly.

*9

On machines with cab mounted brake servo, disconnect the brake pipe R and servo hose H (shown at Y).

Check that all cables are connected and correctly adjusted. Make sure that they are routed and secured correctly. Torque Settings Item L, M, N, P

Nm 244

kgf m 25

lbf ft 180

Cap all open hoses and pipes to prevent fluid loss and ingress of dirt. 10

Disconnect hitch cable J (if fitted).

IMPORTANT NOTE: AIR CONDITIONING If the machine is fitted with air conditioning DO NOT attempt to disconnect any of the hoses until the refrigerant has been discharged.

X

! 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.

K

4-3-4-1/2

A314440

9803/3630

Issue 2*


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.

A

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).

B

C E

Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut. 6

Remove the installation tool.

D

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

M10

13

1.00 - 3.50 3.50 - 6.00

23.00 26.00

13.10

S150970

Note: In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.

9803/3630

Issue 2*


Section B

www.WorkshopManuals.co.uk Body & Framework Cab

3-1


3-1

Direct Glazing Note: If the rear window emergency exit has been used then the complete assembly must be replaced. For ease of fitment and to prevent the rear window from bending tape a piece of plywood to the glass. The following procedures explain how to correctly remove and install panes of glass that are directly bonded to the cab frame apertures. When carrying out the procedures, relevant safety precautions must be taken. 1

Always wear safety glasses during both removal and replacement.

2

Use protective gloves - heavy duty leather gauntlet type gloves when cutting out the broken glass; 'non-slip' type gloves when handling/moving panes of glass; surgical type gloves when using the polyurethane adhesives.

3

Wear protective overalls.

4

DO NOT smoke - the activators and primers used in the procedures are highly flammable.

5

Do not attempt to handle or move panes of glass unless you are using glass lifters (see Service Tools, 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 roof glass on the Loadall 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

9803/3630

Issue 1


Section B



Cab

3-2

3-2

Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) 1

Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.

2

a Laminated glass - leave installed until the old sealant has been cut away, after which it will be possible to lift the broken screen away from its frame housing in one piece.

A

S186380

b Toughened glass - remove as much of the shattered glass as possible prior to cutting out the old sealant. 3

Cut out the old sealant, leaving approximately 1 to 2 mm on the cab frame. There are several tools and techniques for doing this:

B

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.

D C

D

Note: This tool must not be used on toughened glass (see WARNING on previous page). (i) Press the handle to start the knife blade oscillating.

E

E D

(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.

S189870

b 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). (i) Insert the steel tube C into the old sealant on the inside of the glass.

C

(ii) Insert the braided cutting wire D down the centre of the steel tube. If necessary, from the outside, cut out local sealant at the point of the tube to gain access to the wire. (iii) Using suitable pliers, pull the cutting wire through the sealant to the outer side of the glass.

S189880

(iv) Secure each end of the braided cutting wire in the special handles E. (v) Move the cutting wire backwards and forwards in a sawing motion and at the same time gently push or pull the wire to cut through the old sealant.

9803/3630

Issue 1


Section B


3-3


3-3

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.

F

(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.

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.

S189890

(ii) Pull the knife along and cut out the old sealant. Note: There are other tools available to cut out the old sealant. For example, there is a long handle type craft knife to give extended reach. Refer to Service Tools, 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.

9803/3630

Issue 1


Section B


3-4

Direct Glazing (cont'd) Preparing the New Glass


3-4

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

9803/3630

Issue 1


Section B


Section B www.maskinisten.net

Cab

3-5

3-5

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

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

S

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

10-15mm

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.

8-10mm c Pierce the front 'nozzle' end of the cartridge to its maximum diameter.

A186410

d Fit the pre-cut nozzle shown at S. e Install the cartridge in the applicator gun. Note 2: Cold material will be very difficult to extrude. The cartridges must be pre-heated in a special oven (see Service Tools) for 1 hour to a temperature of 80°C (176°F). Preheating 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.

T

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'.

X

Installing the New Glass *1 2

S189930

Make sure the two spacer blocks are in position (see step 1 of Preparing the New Glass). Install the glass in the frame aperture: a ALWAYS use the special lifting tools when moving the glass. 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.

9803/3630

S189910

Issue 1


Section B


3-6


3-6

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 Clean the glass using a purpose made glass cleaner. 6

On completion of the glass installation procedures tidy the work area: a Remove ALL broken glass from the cab area. b Remove the protective covers from the cab seat and control pedestals. c Renew all 'warning' and 'information' decals so that the new installation conforms with the original cab installation.

9803/3630

Issue 1


Section B



4-1

4-1

Fuel Tank Replacement

! WARNING Make the machine safe before getting beneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake engaged and the transmission is in neutral. Disconnect the battery. Chock both sides of all four wheels. 5-3-2-1

Replace the tank by reversing the removal procedure. Make sure hoses C are fitted the correct way round, as marked during removal. If the tank sender unit has been removed, it should be refitted with the float arm orientated towards the front of the machine.

Removal 1

Remove steps A and battery cover B.

2

Disconnect and remove the battery.

3

Remove drain plug and drain fuel tank.

4

Disconnect fuel feed and return hoses C. Label the hoses to ensure correct assembly.

5

Disconnect fuel sender D.

6

Undo clip E securing filler pipe to tank.

7

Support the tank, remove nuts F and bolts G to remove restraining straps H.

8

Remove fuel tank from machine.

If the integral fuel strainer is blocked due to contaminated fuel, remove the strainer and discard. Fit new fuel strainer to the fuel sedimenter. See Fuel Strainer. Use new seal when fitting drain plug.

B

Refill with clean fuel and check for leaks.

E

A G

D C C

H

F

S259450

9803/3630

Issue 3*


Section B



4-2

4-2

Fuel Strainer The strainer can be relocated inside the fuel sedimenter to improve service access for removal and cleaning. The following procedure describes the fitting of a new strainer within the fuel sedimenter. The strainer in the fuel tank must be discarded.

1

Position the machine on firm level ground and apply the parking brake. Switch off the engine and remove the starter key.

2

Locate the fuel sedimenter and clamp the fuel inlet hose to prevent loss of fuel. The inlet hose can be identified by the direction arrow on the top of the sedimenter, as shown at A.

3

Drain the fuel from drain plug B. Support bowl C. Unscrew Nut D to remove the bowl.

4

Fit spring 1, washer 2, o-ring 3 and strainer 4 as shown. DO NOT compress the spring when fitting the o-ring and strainer.

5

Re-assemble the sedimenter. Make sure gasket E is seated correctly.

6

Remove the clamp from the fuel inlet hose and prime the system. See Priming the System (Section 3).

7

Start the engine. Check for correct operation and leaks.

E

4 3

D

2 1

A

C

331290

B

275120

9803/3630

Issue 1*




www.maskinisten.net

Section B



Accelerator Cable

5-1

5-1

D

C

E A B

A335360

9803/3630

Issue 1


Section B



Accelerator Cable

5-2

5-2

Note: One end of the cable is located outside the cab, below the heater, between the cab and the chassis. The other end is attached to the fuel injection pump on the front of the engine. Access to the cab end of the cable is limited. Access can be improved by removing the cab front panel.

Removal 1

Park the machine on firm level ground and engage the parking brake.

2

Raise the boom and fit the safety strut. See Machine Safety (Section 3).

3

Stop the engine and remove the starter key. Raise the engine cover.

! WARNING The engine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6

4

Remove locking pin A and withdraw clevis pin B.

5

Loosen locknuts C (13 mm AF). Screw the locknut to the bottom of the threaded section on the outer cable.

6

Lift the outer cable through the bracket and pass the inner cable through the slot in the front of the bracket.

7

Loosen locknut D and lift the cable through the slot in the support bracket.

8

Disconnect the spring from the arm on the fuel injection pump and withdraw the cable.

Replacement Replacement is the reverse of the removal procedure. Fit clevis pin B as shown and secure with locking pin A. Set the outer cable for maximum extension as shown and secure with locknut C. Adjust the cable as described below.

Adjustment Adjust the cable using locknut D. Remove any slack in the cable without moving lever E from its set position.

9803/3630

Issue 1




www.maskinisten.net

Section B

www.WorkshopManuals.co.uk Body & Framework Air Conditioning Option

7-1

Technical Data


7-1

0

Binary Switch Settings: Low pressure: High pressure:

2.06 bar (29.87 lbf in2, 2.10 Kgf cm2) 27.5 bar (398 lbf in2, 28.0 Kgf cm2)

Thermostatic Switch Settings: Cut out: Cut in:

32.0°F to 34.0°F (0°C to 1.1°C) 44.0°F to 46.0°F (6.6°C to 7.7°C)

Refrigerant: 800 grammes of R134a Gas Ozone Depleting Potential (ODP): Global Warming Potential (GWP):

Zero 0.1

Oil: Type:

PolyAlkylene Glycol (PAG)

Quantity: Recharge the system: 1.5 fluid oz (42.6 millilitres) Component replacement: Condenser Evaporator Hoses Receiver Drier Compressor

2.0 fluid oz (56.8 millilitres) 3.0 fluid oz (85.2 millilitres) 2 to 4 fluid oz (56.8 to 113.6 millilitres) 2.0 fluid oz (56.8 millilitres) None - pre charged

9803/3630

Issue 1


Section B


7-2


7-2

Safety Procedures The air conditioning system includes a pressurised closed circuit containing a non-CFC, environmentally friendly refrigerant, Type R-134a. Any service procedure which breaks into the closed circuit and therefore requires discharging of the system, must only be carried out by service personnel with specialist knowledge of air conditioning systems. The following guidelines should be adhered to by all personnel servicing the air conditioning system.

! WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant. 4-3-4-1/2

! CAUTION Do not operate the air conditioning system when there is no refrigerant in the system, otherwise the compressor will be damaged.

5

When charging or discharging the refrigerant system refrain from smoking. Naked flames must not 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 that 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.

!WARNING PAG type oil is an irritant. It can cause skin irritation. Breathing PAG vapour can cause irritation of the eyes, nose and lungs. Prolonged inhalation can cause drowsiness. BF 1-11

!WARNING

4-3-4-4

1

2

It is critical that the correct refrigerant (R-134a) is used and that charging is done only by qualified personnel. As a precaution, in case of accidental leakage, discharging and charging of the vehicle refrigerant system must be conducted in a well ventilated area.

PAG oil vapour is extremely flammable. Do not smoke or eat near PAG contaminated material. Exercise caution when working around hot and moving engine parts. BF 1-12

Containers of refrigerant should be stored in a cool environment away from direct sunlight.

!WARNING Do not carry out welding operations close to the air conditioning refrigerant circuit. A poisonous gas is produced when refrigerant comes into contact with naked flames. Do not smoke or allow naked flames close to the refrigerant circuit. BF 1- 9

3

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

4

Do Not steam clean refrigerant system components.

9803/3630

Issue 1


Section B




7-3

7-3

General Description 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.

Air conditioning system power is generated from the engine, via an electromagnetic clutch to the compressor. Three switches, connected in series, are included in the clutch supply line, all must be closed for the clutch and therefore the air conditioning system to operate. Compressor

The air conditioning system is a closed circuit through which the refrigerant is circulated, its state changing from gas to liquid and back to gas again, as it is forced through the system.

The compressor A draws in low pressure refrigerant gas from the suction line (evaporator to compressor) and increases refrigerant pressure through compression. This process also increases the refrigerant temperature.

The major components of the system are: A B C D E F G

Compressor Condenser Receiver drier Sight glass/moisture indicator Binary switch Thermostatic Expansion Valve (TEV) Evaporator coil

Operate the air conditioning as described in the Operator Handbook. * Machines from 784535

* Machines to 784534

D F F

G

G

E

C

C B D

B

E A

A

390200

S279502

9803/3630

Issue 2*


Section B


7-4


7-4

Condensor

Thermostatic Expansion Valve (TEV)

High pressure refrigerant is forced from the compressor to the condenser B, which is mounted in the engine compartment. Ambient air is drawn across the condenser by the engine cooling fan. In the condenser, the refrigerant changes state to a high pressure, high temperature liquid but with a lower heat content.

The high temperature, high pressure refrigerant is forced by compressor action into the Thermostatic Expansion Valve (TEV) F, which meters the amount of refrigerant entering the evaporator. As the liquid passes through the valve, it immediately undergoes a reduction in pressure.

Receiver Drier The refrigerant passes through the receiver drier C, which contains a desiccant to remove moisture from the system. The receiver drier serves as a reservoir for refrigerant and also includes a filter to remove foreign particles from the system. Sight Glass/Moisture Indicator A combined sight glass and moisture indicator D changes colour when moisture contamination is present: GREEN: LIGHT GREEN: YELLOW:

Dry Caution Wet

The sight glass provides a quick indication of the refrigerant condition. Note: The sight glass does not always positively identify a problem. Further diagnosis using manifold gauges, or an appropriate charging station, is required to fully identify a problem.

This pressure drop causes a portion of the liquid to vapourise, which absorbs heat from the surrounding liquid. The temperature of the liquid will then drop creating a mixture of liquid and vapour at low temperature and pressure. This then enters the evaporator. Evaporator The refrigerant is drawn through the evaporator coil G by the suction of the compressor. The temperature of refrigerant is now considerably below that of the air being drawn across the evaporator coil by the blowers. 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. Moisture in the air condenses on the evaporator coil and is drained away via condensate. Cool de-humidified air is emitted through air vents into the cab. The low temperature, low pressure, high heat content refrigerant gas, is now drawn by suction back to the compressor, where the cycle is completed. .

Binary Pressure Switch The binary switch E is a low pressure switch designed to open at approximately 2 bar (30 lbf in2) and a high pressure switch designed to open at 26 bar (377 lbf in2). When the refrigerant pressure is within the 2 bar and 26 bar limits, the switches will be closed and, providing the thermostatic expansion valve and on/off switches are closed, a current will be supplied to the field coil of the clutch. Through electro-magnetic action the field coil clutch will be pulled towards the compressor clutch and the refrigerant cycle will commence. Pressure Switch Settings

Low pressure: High pressure:


9803/3630

Issue 1


Section B


7-5


7-5

Refrigerant Refrigerants are the basic ingredient of all air conditioning systems and are used to transfer the heat energy around the system. Refrigerant type R134a is used in the air conditioning system. Its full chemical name is: 1, 1, 1, 2-Tetraflouroethane (CH2FCF2) R134a is a HFC (hydrFlouroCarbon) and is non-toxic, nonflammable and non-explosive at normal atmospheric temperature and pressure. It can be flammable under certain pressure and air mixtures. Refer to the safety procedures at the front of this section before handling refrigerants. Good installation practice is required to avoid the release of refrigerant into the atmosphere. Refrigerant R134a contains no chlorine and has an Ozone Depleting Potential (ODP) of zero, and a Global Warming Potential (GWP) of 0.1.

Refrigerant Oil The system requires a PAG type refrigerant oil to lubricate the compressor. The oil mixes with the refrigerant and is carried around the system. It is important that the recommended grade of refrigerant oil is used. Mineral oil is not suitable for R134a refrigerant systems. Do not mix oil types. The compressor is supplied with an oil charge, but additional oil (56.8 millilitres) will be required when the receiver drier is replaced. The oil is added to the compressor through the oil filling plug before the evacuation procedure is started. Only use fresh, unused oil. Oil that has been exposed to the air will have absorbed water.

9803/3630

Issue 1


Section B


8-1

Control

* Leak

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. Current is fed to the field coil through three series switches whose contacts are controlled by the following: 1

The manual switch F in the cab

2

The thermostat switch monitoring the evaporator temperature

3

The high and low level pressure switches

Switch F will start the refrigeration cycle provided that the ambient temperature in the cab is greater than 0°C and the refrigerant pressure remains within the specified limits. The thermostat has its sensor inserted in the evaporator coil. It controls the refrigeration cycle by switching the compressor clutch on and off to prevent freezing of the condensate on the evaporator coil. The pressure level switches are housed in a common assembly located below the sight glass. If the refrigerant pressure exceeds the upper pressure limit specified or falls below the lower limit, the contacts will open and the clutch will disengage, closing down the refrigeration cycle. Pressure Switch Settings Low pressure High pressure



8-1

Testing ! WARNING

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

Note: The refrigerant is heavier than air and will leak downwards from the defective component. Check in still conditions but in a well ventilated area. Hose or pipe connections are likely leakage points of any refrigerant circuit. It is essential that an electronic leak 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 the suspect area. `To test for leaks in the high pressure side of the system i.e. from the compressor output to the expansion valve, run the air conditioning for a few minutes then switch off the engine and test for leakage using an electronic leak detector or soapy water. 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.

F

Hoses are used to connect the inlets and outlets of the compressor, condenser, receiver drier and expansion valve (the evaporator coil is connected to the expansion valve within the air conditioning unit using rigid pipes). If leakage is detected from a hose connector, either by means of an electronic leak detector or soapy water, tighten the connector up and repeat the leakage test. If leakage is still evident, it will be necessary to discharge the system and renew the connector 'O' ring seal.

S263241

9803/3630

Issue 2*


Section B




8-2

8-2

Service Ports Service ports A, fitted with quick coupling type valves, are incorporated into the refrigerant lines at the compressor. These allow either a manifold gauge block or an appropriate charging station to be connected to the system for charging, evacuation, maintenance and diagnostic purposes. Procedures for charging and discharging the system are not given in this manual as they require special equipment and training. The valves contain a non-return valve to prevent refrigerant loss when connecting to the system. Protective caps are provided for the ports when not in service. The caps must be in place to reduce leakage and prevent damage to the valve cores.

* Machines from 784535

* Machines to 784534

A

A A

A

391230 297920

9803/3630

Issue 2*


Section B




8-3

8-3

Evaporator Removal The evaporator unit contains a blower, evaporator and Thermostatic expansion valve. It is located beneath the right hand front side of the cab. Removal

! 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.

Refitting Refitting the evaporator unit is the reverse of the above procedure. Recharge the air conditioning system and check for leaks. Refill the cooling system and check for leaks.

A

4-3-4-1/2

A

Complete removal of the evaporator unit will require the refrigerant to be evacuated from the system.

B

Access to the thermostatic expansion valve can be gained by lowering the evaporator unit without disconnecting the hoses. In this instance the refrigerant need not be evacuated. 1

Raise the boom and fit the safety strut. See General safety, Section 3.

2

Drain the cooling system.

3

Unscrew bolts A and remove the instrument panel B.

4

Disconnect the heater control knobs C.

5

Disconnect the electrical connections at D.

6

Disconnect heater hoses E at the heater tap, and heater hose F at the evaporator.

7

Disconnect air conditioning hoses G at the expansion valve.

8

Remove bolts H and J securing the evaporator to the machine.

A

C

A

C

S251510

H

D

F

J

G G

E S251500

9803/3630

Issue 1


Section B




8-4

8-4

Thermostat Removal The Thermostat monitors the external temperature of the evaporator and is located in the air conditioning unit. Access to the thermostat can be gained without evacuating the refrigerant from the system. Removal 1 Raise the boom and fit the safety strut. See General safety, Section 3. 2 Lower the evaporator unit, as described previously. 3 Gently remove the sensor wire A from between the evaporator fins. 4 Electrically disconnect the thermostat at B. 5 Remove the two screws C securing the thermostat to the evaporator housing.

Refitting Refitting is the reverse of the above procedure. Gently insert sensor wire A between the evaporator fins.

B C

C A

S251501

9803/3630

Issue 1


Section B


8-5


8-5

Binary Pressure Switch If the binary switch is suspected of being faulty, the fault may be due to an electrical fault or incorrect system pressure. Check the refrigerant charge level and test the switch, as described below: Binary Switch Testing

! 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

1

Switch off the engine and electrically disconnect the pressure switch at A.

2

Connect a link wire between the two electrical cables.

3

Switch on the engine and air conditioning system. If the system operates, one of the pressure switches in the binary switch is faulty. If the system fails to operate check the electrical connections.

4

Removal

Refit the binary switch. If the clutch still fails to operate, check all electrical connections.

Machines to 784534

1

Disconnect the electrical connections at A and unscrew the pressure switch B.

Refitting 1

Screw the binary switch into the pressure switch port and tighten sufficiently to form a gas tight seal.

2

Re-connect the electrical connections.

3

Operate the air conditioning system and check the pressure switch for leaks. If leaks are found, tighten the switch further until the leak stops.

Machines from 784535

A

B

B

A

298610 391240

9803/3630

Issue 2*


Section B




9-1

9-1

Service Checks The air conditioning system needs to be checked regularly to ensure efficient and safe operation. Before commencing any service operations, carry out a basic service check as described below:

Off-Season Operation During the off-season, the air conditioning system should be operated for at least five minutes every month to circulate the oil in the system to lubricate the fittings and seals. When operating the system, ensure that:

1

Start the engine and operate at fast idle speed (1000 RPM).

2

Switch on the air conditioning and set to maximum cooling.

1 2 3 4

Engine idle speed is greater than 1000 RPM. Ambient temperature is greater than 0°C. Cab temperature is greater than 20°C. The engine is at normal operating temperature.

Note: The cab temperature needs to be above 20°C. At low ambient temperatures it may be necessary to operate the heating system to prevent the air conditioning system switching off. 3

Operate the engine at operating temperature for five to ten minutes.

4

Check the condition of the refrigerant through the sight glass. The sight glass should be clear. If there are bubbles after the compressor clutch has engaged for at least 15 seconds, then the refrigerant level could be low.

5

Close the cab door and windows and allow the internal temperature to stabilize.

6

Measure the temperature at the evaporator outlets. The temperature should change as the compressor clutch cycles in and out. The outlet temperature with the clutch engaged should be significantly below ambient (4°C to 10°C) rising by 6°C to 8°C when the clutch disengages.

7

Check the sight glass/moisture indicator. If no moisture is present it should be clear, otherwise a full service will be required.

8

Stop the engine when the tests are complete.

9803/3630

Issue 1


Section B


9-2


9-2

Cleaning the Condenser * Machines to 784534 If the condenser tubes/fins become clogged, the radiator will be less efficient. Brush off all debris from the cooler tubes and fins using a soft bristle brush. Make sure the loosened material is brushed out of the cooler enclosure. Open the engine cover to clean both sides of radiator A. Unclip and remove guard B. Release fastener C and hinge condenser assembly to the rear. Clean both sides of radiator A and condenser D. When clean, close and secure condenser assembly, refit and secure guard B.

B A

D C

9803/3630

Issue 3*


Section B




9-3

9-3

Cleaning the Condenser Machines from 784535 If the condenser tubes/fins become clogged, the radiator will be less efficient. Brush off all debris from the cooler tubes and fins using a soft bristle brush. Make sure the loosened material is brushed out of the cooler enclosure. Open the engine cover to clean both sides of radiator A. Release wingnuts B and hinge condenser assembly forwards and downwards. If necessary, slacken bolts C (both sides) to enable the condensor to move. Clean both sides of radiator A and condenser D. When clean, close and secure condenser assembly.

A B

B

D C 387282

C

9803/3630

Issue 3*


Section B




9-4

9-4

Wiring Diagram Harness Wires Use the illustration below to complete continuity checks on the air conditioning system and heater harness wiring. Key F4 F5

15A 15A

1 2 3 4 5 6 7

Heater/air conditioning fan Heater/air conditioning unit Air conditioning switch Face level fan Compressor Air conditioning relay Binary pressure switch

335600

9803/3630

Issue 1


Section B




10 - 1

10 - 1

Fault Finding * The following fault finding checks can be undertaken without discharging the air conditioning system. Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. To locate faults on the system it is recommended that an electronic leak detector and refrigerant pressure gauges should be used. However, leaks can be detected using a soapy water applied to the suspected leak. System condition can be assessed by inspecting the refrigerant passing through the sight glass. Sight Glass Indications * The sight glass A (to machine 784534) or B (from machine 784535) should be clear with no bubbles during normal operation.

Other sight glass indications are shown below: Clear - No fault indicated unless the system is unable to provide cool air. The indication then is that the system is completely discharged of refrigerant.

Foam or Bubbles - Refrigerant low and in need of charging or air in system.

Cloudy - Desiccant breakdown in the receiver dryer.

Note: Sight glass indications cannot always give a positive identification of a problem. Further dianosis, preferably by a refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.

B

A S297430

390200 390200

9803/3630

Issue 2*




www.maskinisten.net

Section B




10 - 2

10 - 2

General Fault Indications a)

Poor performance

Low system pressure. Condensor coil air flow restricted.

Discharge and recharge the system Remove debris from coil using compressed air.

Air filter blocked.

Clean with detergent and water.

Compressor drive belt too slack.

Adjust belt tension.

b)

Warm or slightly cool air emitted from unit

Expansion valve stuck open or closed.

Renew expansion valve.

c)

Blower operates on fan speed 2 only.

Blower resistor failed Blower motor failed

Renew resistor. Renew complete blower motor unit.

Blower does not operate

Fuse blown

Replace fuse and re-test.

Compressor clutch continually cuts out

Condensor coil blockage.

Remove debris from coil/renew compressor.

Overcharging of refrigerant system.

Discharge and recharge the system.

Blocked expansion valve/condensor.

Clear blocked component.

d)

See Routine Maintenance , Section 3 for details of compressor drive belt adjustment and cleaning the air conditioning filter.

9803/3630

Issue 1


Section B




10 - 3

10 - 3

Fault Finding Chart No Air Conditioning: CHECK

ACTION

1

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

YES: NO:

Check 2 Reset controls and re-test

2

Is the air conditioning blower working ?

YES: NO:

Check 3 Check 9

3

Is the compressor running ? - visually check pulley/clutch.

YES: NO:

Check 10 Check 4

4

Is the compressor fuse blown ?

YES: NO:

Renew fuse F5 and re-test Check 5

5

Is there a 12V supply at the pressure switch ?

YES: NO:

Check 6 Check 7

6

Does the compressor clutch engage with the pressure switch assembly bypassed ?

YES: NO:

Replace pressure switch assembly Check 8

7

Does the clutch engage with the thermostat switch bypassed ?

YES: NO:

Renew the thermostat switch and re-test Check all electrical connections

8

Is there a 12V supply at the compressor ?

YES: NO:

Renew the compressor clutch and re-test Renew the compressor relay and re-test

9

Are the blower switch and wiring OK ?

YES: NO:

Renew complete blower unit Renew switch or wiring

10

Is the condensor air flow blocked ?

YES: NO:

Clean condensor and radiator Check 11

11

Is the evaporator air flow blocked ?

YES: NO:

Clean filter and, if necessary the evaporator Check 12

12

Is sight glass indication OK ?

YES: NO:

Renew the compressor Check the refrigerant charge

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics

i

www.maskinisten.net Section C

i

Contents

Page No.

Technical Data - Relay Identification * - Fuse Identification

1-1 1-2 1-7

Harness Repair

4-1

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

5-1 5-3 5-3 5-3 5-4

Batteries - Warning Symbols - Safety - Maintenance - Specific Gravity Test - Battery Testing

6-1 6-2 6-2 6-3 6-3

Alternator - Charging Circuit Test - Alternator Charging Test - Terminal ‘W’ Output Test - Service Precautions - Removal and Replacement - Dismantling and Assembling (Lucas) - Dismantling and Assembling (Magneti Marelli)

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

Starter Motor - Starting Circuit Test - Removal and Replacement - Dismantling and Assembling

8-1 8-3 8-3

Water Temperature Sender and Switch

9-1

Safe Load Indicator and Load Moment Indicator - Introduction - Calibration - SLI System - Calibration - LMI System - Fault Finding Diagnostic Fault Codes - LMI Systems only Fault Finding Chart - SLI and LMI Testing - SLI and LMI Transducer - Removal and Replacement

10 - 1 10 - 4 10 - 5 11 - 1 11 - 2 11 - 3 11 - 6 12 - 1

Parking Brake Switch - Adjustment

13 - 1

Proximity Switch - Adjustment - Sensor Mounting

14 - 1 14 - 1

9803/3630

Issue 7*


Section C


ii


ii

Contents

Page No.

* Electronic Control Unit (ECU) - Four Speed Transmission

- General Description - ECU Replacement - ECU Mounting - Fault Finding - Checking Solenoid Operation - Solenoid Identification - Checking for (+VE) Supply to the Solenoids - Checking the Mainframe Harness - Checking the Park Brake Switch - Checking the Transmission Dump Switch - Simplified ECU Installation - Handheld Mark II Test Unit * - ECU Factory Default Settings

15 - 1 15 - 1 15 - 1 16 - 1 16 - 2 16 - 2 16 - 2 16 - 3 16 - 4 16 - 4 17 - 1 17 - 2 17 - 3

* Electronic Control Unit (ECU) - Five Speed Transmission

- General Description - ECU Replacement - Five Speed Operation - Fault Finding - Checking Solenoid Operation - Checking for (+ve) Supply to the Solenoids - Solenoid Identification - Checking the Mainframe Harness - Checking the Park Brake Switch - Checking the Transmission Dump Switch - Simplified ECU Installation - Using the PC Diagnostic Tool - Operation - ECU Diagnostic Screens

18 - 1 18 - 1 18 - 1 18 - 2 18 - 3 18 - 3 18 - 3 18 - 4 18 - 6 18 - 6 18 - 7 18 - 8 18 - 8 18 - 9

* Speed Sensor

- Checking Speed Sensor Operation - Fault Finding Guide

19 - 1 19 - 2

* Speedometer

- Calibration Procedure

20 - 1

* Harness and Wire Number Identification

- Wire/Harness Number Explanation

24 - 1

9803/3630

Issue 7*


Section C


iii


iii

Contents

Page No.

Electrical Schematics - 530 Machines without Neutral Start Relay (Serial No. 767001 to 768836) 25 - 1 - 530 Machines with Neutral Start Relay and ECU Controlled Transmission (Serial No. 768837 to 770053) 26 - 1 - 530 Machines with Relay Controlled Transmission, ECU Not Fitted (Serial No. 770054 to 770958) 27 - 1 - 530, 540 Sway Machines (from Serial No. 770959) 28 - 1 - 530, 540 Non-Sway Machines (from Serial No. 770959) 29 - 1 - 530, 540 machines with Manual Auxiliary Controls (from Serial No. 775402) and 535 Machines (from Serial No. 777362) 30 - 1 - 530, 540 Machines with Single Lever Controls (SLC) (from Serial No. 775402) 535 Machines (from Serial No. 777362) 31 - 1 - 530FS Super, 540FS Super, 530 SXL, 540 SXL 32 - 1 33 - 1 * - 533-105 Machines Note: Additional electrical schematics for the Smooth Ride System (SRS) can be found in Section E.

9803/3630

Issue 2*




www.maskinisten.net

Section C

www.WorkshopManuals.co.uk Electrics Technical Data

1-1 Battery Cold Crank amps for 1 minute to 1.4 VPC at -18°C (0°F) Reserve capacity (minutes) for 25 amp load

12 volts, negative earth

Alternator Starter Motor Light Bulbs Headlights main/dip Working lamps Front side lamps Stop/tail lamps/reverse Indicator lamps Number plate lamp Fog lamp Interior lamp Panel/warning lamps Beacon

A127-65, 65 amp maximum output M127 12 volt


1-1

410 to 58 170 to 230

45W/40W or 60/55W (halogen) 55W (Halogen) 5W 21W/5W/21W 21W 10W 21W 18W 1.2W 55W

9803/3630

Issue 2


Section C



Technical Data

1-2

1-2

Relay Identification Relays are used in the electrical circuits for a variety of reasons. The most usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this causes internal contacts to open or close which controls a larger current in another circuit. Although relays look similar, internally they can be different, for example, they can be single or double contact; normally closed or open. Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function correctly. The relays are identified as follows

1

530 only (from S/N 767001 to S/N 768836) (Without Neutral Start) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Audible alarm Reverse lights Starter Hazard warning lights Side lights Air conditioning Sway isolation Auxiliary change-over Auxiliary A Auxiliary B Retract Extend 2 Wheel drive brake -

4

90

2

56 !@ %^

3

78 £$ &*

530 only (from S/N 768837 to S/N 770053) (With Neutral Start) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Audible alarm Neutral start Starter Hazard warning lights Side lights Air conditioning Sway isolation Auxiliary change-over Auxiliary A Auxiliary B Retract Extend Reverse 2 Wheel drive brake -

A335670

NOTE: ECU deletion cut-in numbers are transmission dependant. Transmission Part Number

Serial Number of cut-in

449/06100 449/06200 449/06300 449/06400 449/06500 449/06600

770055 770065 770053 770069 770063 770093

9803/3630

Issue 4*


Section C


1-3

Relay Identification - continued

7 7

1-3

530 only (from S/N 770054 to S/N 770958) 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

1 1


Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Auxiliary change-over 2 Auxiliary change-over Forward relay Reverse 1 Reverse 2 2 wheel drive brake Auxiliary A Auxiliary B Retract Extend Forward HI/LO Reverse HI/LO Drive Driveshaft

16 & 17 ^

2 2

18 ( 19 8 9 9 8 *

3 3

10 ! 11 ) 20 ⁄ 21 0

4 4

22 ‹ 23 12 £ 13 ¤ @

5 6 6 14 % 15 › 24 fi 25 5 $ A335680

9803/3630

Issue 4*


Section C



Technical Data

1-4

1-4

Relay Identification - continued 530/540 (from S/N 770959 onwards) 535 (from S/N 777362 onwards) * 533-105 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Forward relay Reverse 1 Reverse 2 Two wheel drive brake relay Auxiliary change-over Sway isolation Forward HI/LO Reverse HI/LO Drive Driveshaft

1

7

2

4

5

9

14 15

10 11

16 17

12 13

18 19

8

3

6

360940

9803/3630

Issue 5*


Section C



Technical Data

1-5

Relay Identification - continued

530, 540 Fitted with Smooth Ride System (SRS) 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

1

7

18 19

3

10 11

20 21

4

12 13

22 23

5

14 15

24 25

8

6

Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Dump Parkbrake Hazard warning lights Sidelights Air conditioning Forward relay Reverse 1 Reverse 2 2 wheel drive brake Auxiliary change-over Sway isolation Forward HI/LO Reverse HI/LO Drive Driveshaft Neutral Dump SRS SRS relay

16 17

9

2

1-5

A335680

9803/3630

Issue 3*


Section C


1-6 * Relay


1-6

Identification - continued

530FS Super and 540FS Super Machines with Five Speed Powershift Transmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Audible alarm Neutral start IGN Feed 1 IGN Feed 2 Hazard warning lights Sidelights Air conditioning Auxiliary change-over Sway isolation Reverse 2 Two wheel drive brake relay Neutral relay Dump relay Smooth Ride System SRS relay -

1

5

2

6

7

12 13

3

8

9

14 15

4

10 11

16 17 A372461

9803/3630

Issue 2*


Section C



Technical Data

1-7

1-7

Fuse Identification This illustration shows a typical fuse installation. The electrical circuits are protected by fuses. The fuses are located in a fuse box, as shown. If a fuse blows, find out why before fitting a new one. Additional fuse links are fitted at the battery positive terminal. Note: The radio fuse may have a higher rating, depending on the type of radio fitted. Check radio fitting instructions.

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

Circuit Boom isolator Joystick controls Safe Load Indicator (SLI)/Load Moment Indicator (LMI) Heater Air conditioning, face fan Wipers Clock, radio, heated seat Instrument panel Direction Indicators Auxiliary hydraulics

Rating 7.5 10 5 15 15 15 5 7.5 10 7.5

16 17 18 19 20

Starter relay 5 Engine shut-off solenoid (ESOS) 5 Steer mode selector 7.5 Powershift 15 2/4 Wheel drive selector 5 2/4 Wheel drive selector with trailer electrics (530) 10 Auxiliary socket 10 Brake lights 10 Rear work light 7.5 Reverse lights, reverse alarm 7.5 BLANK

21 22 23 24 25 26 27 28 29 30

Right hand side lights Left hand side lights Dip beam lights Main beam lights Front working light Rear fog light BLANK Horn, Headlight flash Warning beacon, Interior light, Radio Hazard lights

31 32 33 34 35 36 37 38 39 40

Smooth Ride System (if fitted) SPARE SPARE Air suspension seat (if fitted) SPARE BLANK BLANK BLANK BLANK BLANK

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

A348080

10 10 10 10 10 5 10 5 15 5

15

9803/3630

Issue 1


Section C



Technical Data

1-8

1-8

Fuse Links From Serial Number 768700 - 770053

A B C D E

Circuit Horn, Hazard warning lights, Beacon, Interior light Road lights, Working lights Not used ESOS, Forward/reverse switch, Brake lights SLI, Heater, Wipers, Radio, Instruments

Rating 30 30 40 80

D

From Serial Number 770054 onwards

A B C D E

Circuit Horn, Hazard warning lights, Beacon, Interior light Road lights, Working lights SLI, Heater, Wipers, Radio, Instruments ESOS, Forward/reverse switch, Brake lights Not used

B A

Rating 40 40 40 40 80

9803/3630

C

E S245111

Issue 1


Section C



Harness Repair

4-1

4-1

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

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.

Procedure 1

Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed opposite, 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.

! CAUTION

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.

ELEC 2 - 1

! WARNING

1 1 50 50 50

IP67 Electrics Service Kit Part No. 892/00307, is no longer available, refer to Service Tools, Section 1.

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.

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 .

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)

3

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

....continued

ELEC 2 - 2

7 !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

Issue 1

9803/3630


Section C


4-2

Harness Repair


4-2

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.

s n S189490/3

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

F E

S189490/4

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics Harness Repair

4-3


4-3

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

9803/3630

Issue 1


Section C



Test Methods

5-1

5-1

Use Of Multimeter In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter. The approach is based on a fault finding check list. In tracing the fault from the symptoms displayed you will be directed to make measurements using a multimeter. These instructions are intended to cover the use of the recommended multimeters. 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.

AVO 2003

A typical analogue meter

A K

L

A

G1 OFF V/A V/A

H

A

J

C

C

B

C

D

A

+

+

-

-

B

9803/3630

Issue 1


Section C 5-2

www.WorkshopManuals.co.uk Electrics Test Methods


5-2

S153070

9803/3630

Issue 1


Section C



Test Methods

5-3

5-3

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.

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics Test Methods

5-4


5-4

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.

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics Batteries

6-1


6-1

! CAUTION

Warning Symbols The following warning symbols may be found on the battery.

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT- 3- 1-14

Symbol

Meaning

Keep away from children.

! WARNING Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4

! DANGER

A289230

Shield eyes.

Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses. INT-3-2-1/3

A289260

! CAUTION No smoking, no naked flames, no sparks.

Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12

A289280

! WARNING Explosive Gas.

A289250

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

Battery acid.

A289240

Note operating instructions.

A289270

9803/3630

Issue 3*


Section C

www.WorkshopManuals.co.uk Electrics Batteries

6-2


6- 2

Maintenance

Safety

! WARNING Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first. When reconnecting, fit the positive (+) lead first. Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. First Aid - Electrolyte Do the following if electrolyte:

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

Never allow the electrolyte level to fall below the recommended level - 6 mm (1/4 in) above the plates.

3

Use only distilled water for topping up.

4

Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) - this condition makes recharging the battery very difficult.

Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery: - NEVER boost-charge a maintenance free battery. - NEVER charge a maintenance free battery at a voltage in excess of 15.8 Volts. - NEVER continue to charge a maintenance free battery after it begins to gas.

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

! CAUTION Before carrying out arc welding on the machine disconnect the battery and alternator to protect the circuits and components. The battery must still be disconnected even if the battery isolator is fitted. INT-3-1-13

9803/3630

Issue 2


Section C



Batteries

6-3

6-3

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 0.007 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 Readings 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'.

5

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).

Note: Do not hold the switch in the LOAD position for more than 10 seconds. 6

Ensure that the battery is completely disconnected from the vehicle.

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 9V.

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.

4

Set the CHECK/LOAD switch A to CHECK to read the battery no-load voltage which should be at least 12.4V.

S239510

Fault Diagnosis Battery Tester Readings

Remedy

1

CHECK: 0 - 12.6V LOAD: less than 6V

Renew battery

2

CHECK: 6 - 12.4V LOAD: less than 9V and falls steadily but remains in yellow zone.

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

3

CHECK: less than 10V LOAD: less than 3V

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

4

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

Charge battery which will probably recover.

9803/3630

Issue 1


Section C



Alternator

7-1

7-1

Charging Circuit Test

Check 2

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.

Note: The following checks should be made using an analogue (moving pointer) type meter.

Adjust the alternator drive belt tension if necessary and make sure that the battery is well charged. Turn the start switch to the ON position. 'Oil pressure' and 'No charge' warning lights should glow.

Stop the engine and turn the starter switch to OFF. Withdraw the alternator plug and connect the test meter between the large terminals and 'earth'. With the meter set to measure 12V DC, the meter should show battery voltage. If the reading is zero, check the cables for continuity, particularly at the starter terminals.

If any light fails, proceed to Check 1. Start the engine; all warning lights should extinguish rapidly. If the 'No charge' warning light remains ON proceed to Check 2. If the oil pressure warning remains on STOP ENGINE IMMEDIATELY and investigate the engine lubrication system. 322690

Check 1 With start switch 'ON' try the heater motor and screen wiper.

If the voltage is correct, check the alternator as follows:

If they operate normally, check the warning light bulb for blown filament.

Alternator Charging Test

Simultaneous failure of all items indicates a fault at the start switch. Check for cable disconnection before condemning the switch itself. If the 'No charge' warning bulb is in good order, withdraw the triple plug from the back of the alternator. Make a temporary connection between the SMALL terminal in the plug and earth as shown below. If the 'No charge' warning bulb still fails to light, check the cable for continuity. If the bulb now lights, check the alternator for a defective regulator (see Alternator Charging Test).

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 fuse B2 removed. Install a 100 amp open - type shunt between the battery positive lead and the battery positive terminal. Connect the test meter and select DC Amps range.

S08364

322680

Start the engine and run at maximum speed (see Page K/11). Meter should show maximum alternator output (see Technical Data). Note: The meter reading should be taken as soon as possible after starting the engine, as the charging current will fall rapidly.

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics Alternator

7-2


7-2

A zero reading indicates failure of the alternator and may be caused by one of the following conditions. These are listed in the order of probability. a

Defective suppression capacitor.

b

Dirty slip rings or worn brushes.

c

Defective regulator.

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 sliprings 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.

Terminal 'W' Output (Tachometer) Test With the test meter set to 12V DC, measure the output at the 'W' terminal as shown. If the reading is less than 7V DC the regulator will need to be replaced. If the output reading at the 'W' terminal is satisfactory then the problem would lie with the instrument panel tachometer head.

322700

9803/3630

Issue 1


Section C



Alternator

7-3

7-3

Service Precautions a

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

b

Never make or break connections to the battery or alternator, or any part of the charging circuit whilst the engine is running. Disregarding this instruction will result in damage to the regulator or rectifying diodes.

c

Main output cables are 'live' even when the engine is not running. Take care not to earth connectors in the moulded plug if it is removed from the alternator.

d

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

e

If slave starting is necessary, connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit. The slave battery may then be safely removed after a start has been obtained. Take care to connect batteries positive to positive, negative to negative.

B A

Removal and Replacement S099850A

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.

C

D S099850B

9803/3630

Issue 1


Section C 7-4



Alternator

7-4

S215650

9803/3630

Issue 1


Section C


7-5


7-5

Dismantling and Assembly - Lucas Type 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. 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

kgf m 0.28 0.41 0.35 0.55 6.10

lbf ft 2.0 3.0 2.5 4.0 44.2

9803/3630

Issue 1


Section C



Alternator

7-6

7-6

5 A 4

1 2

3

5

6

7 8

9 £

@

!

0

B

216870

9803/3630

Issue 1


Section C


7-7


7-7

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.

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

9803/3630

Issue 1




www.maskinisten.net

Section C



Starter Motor

8-1

8-1

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 shut off solenoid lead is disconnected at the fuel pump. Check the readings in the following sequence using a voltmeter. Unless otherwise stated, the readings must be taken with the starter switch in the 'start' position and the transmission forward/reverse selector in neutral. 1

Connect the voltmeter across the battery terminals. Reading in 'start' position: 10.0V approximately.

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. If the reading between terminal D and earth is below 8.0V, connect the voltmeter between terminal E and earth. An increase in the reading to 8.0V indicates either a faulty start relay or a fault in the feed from the transmission selector switch to the relay solenoid. Check also the solenoid earth connection. If the reading between E and earth is less than 8.0V, the fault must be in either the starter switch (terminals F and G) or in the wiring between the solenoid, starter switch, and the start relay. 4

A low reading probably indicates a fault in the starter motor. 2

3

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. Connect the voltmeter between the solenoid terminal C and a good earth.

Connect the voltmeter between the battery negative and starter earth connection B. The reading in the 'start' position should be practically zero. If the reading is appreciably above zero, a high resistance in the earth lead or connections is indicated.

5

Connect the voltmeter 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.

Minimum reading in 'start' position: 8.0V. If the reading is appreciably above zero, 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. Finally reconnect the engine shut off solenoid lead.

9803/3630

Issue 1


Section C 8-2

www.WorkshopManuals.co.uk Electrics Starter Motor


8-2

S02043C

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics Starter Motor

8-3


8-3

Removal and Replacement Disconnect cables and remove battery. Remove cables from main starter terminal and solenoid terminal. Unscrew three securing nuts and remove starter. Replace by reversing the removal sequence. Dismantling

Assembling

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.

Soak new bushes 32 and 34 in clean warm engine oil for 24 hours before fitting.

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 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.

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 0.13-1.14 mm (0.005-0.045in.) by slackening locknut 17 and rotating eccentric pin 18 as necessary. Retighten locknut.

Check the field windings for open circuits by connecting an ohmmeter (0 to 100 ohms) 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 in turn. A high or infinity reading indicates a short circuit between the coils and the yoke. Renew the coils as necessary, removing screws 36 with a pole shoe screwdriver C50 (obtainable from Lucas dealers). Check bronze bushes 32 and 34 for wear.

S02303A

9803/3630

Issue 1


Section C



Water Temperature Sender and Switch

9-1

9-1

Water Temperature Sender The water temperature sender is mounted in the engine block as shown at A. If the sender is suspected to be faulty, remove from the machine and carry out a resistance check across the two pins.

A

Dependent on the temperature of the sender, the resistance measured should lie between the two curves shown in table C. If the resistance shows a short or open circuit, replace the sender with a serviceable item.

B

C 3000

Resistance (Ohms)

2500 2000 1500 1000 500 0 0

10

20

30

40

50

60

70

80

90 100 110

Temperature (°C) A313810

Water Temperature Switch The water temperature switch is mounted in the engine block as shown at B. The switch is normally open, but will close if the water temperature rises to 105° ±2°C and will activate a warning buzzer in the cab. The switch will re-open when the water temperature falls to 95° ±4°C.

9803/3630

Issue 1


Section C


10 - 1

Safe Load Indicator & Load Moment Indicator


10 - 1

Introduction The machine is fitted with either an electrical Safe Load Indicator (SLI) or a Load Moment Indicator (LMI).

SLI System

The indicators warn the operator when the machine is nearing its maximum working limit (ie. when it could tip forward). A sensor measures the load exerted on the rear axle and sends a signal to the indicator. Machines destined for the North American market are not normally fitted with a Safe Load Indicator or Load Moment Indicator.

G E D

Testing procedures described in this section should be carried out on level ground with the road wheels in the straight ahead position.

C

Safe Load Indicator

A

When the load carried by the forks is within the maximum working limit in terms of weight and boom extension, the green LEDs C on the display unit will illuminate. As the load nears the maximum working limit, the LEDs illuminate progressively as the load increases and the amber LEDs D will illuminate. When the maximum working limit is reached, the red LEDs E will flash and an audible warning will activate.

S244700A

Load Moment Indicator The LMI system has additional features which are listed below: (a) (b) (c) (d) (e)

LMI System

simplified calibration procedure; increased environmental protection; axle transducer re-located for improved accuracy. user friendly fault diagnosis with error indication showing nature of fault; increased functionality, including alarm volume and LED brightness control;

The indicator converts the signal from the transducer on the rear axle into a display of three green LEDs C, one amber LED D and one red LED E. The LEDs will illuminate progressively as the load increases. All LEDs will flash as the load nears the maximum working limit. If the load exceeds the maximum working limit, the red LED E will illuminate and an audible warning will activate.

E D C G

100%

A

If a system fault is detected, various combinations of LEDs will indicate a fault code. See Diagnostic Fault Codes. LED G remains on whenever power is supplied to the display box. The new LMI display box is not interchangeable with the earlier SLI system.

9803/3630

325920A

Issue 2*


Section C

www.WorkshopManuals.co.uk Electrics *Safe

10 - 2


Load Indicator & Load Moment Indicator

10 - 2

530 A

B

Y

A 0

1000

2000

Z

B

2470

A275010

X

540 A B Y

A B 0

1000

Z

2000

X

9803/3630

2470 300230

Issue 3*


Section C




10 - 3

10 - 3

535-95

A B

Y A B 0

1000

2000

3000

Z

4000

5000

X

9803/3630

A346470

Issue 1


Section C




10 - 3A

10 - 3A

533-105 (Stabilisers Down)

A B

Y Z 0

1000

2000

3000

4000

X 5000

416460

533-105 (Stabilisers Up)

A

B

Y

Z 0

1000

A

X 2000

B 3000

4000

9803/3630

5000

416470

Issue 1




www.maskinisten.net

Section C

www.WorkshopManuals.co.uk Electrics Safe Load Indicator & Load Moment Indicator

10 - 4


10 - 4

Calibration - SLI System Adjustment of Full Scale Setting

Adjustment of Balance Setting 1

! WARNING

Park the machine on firm level ground.

2

Remove any attachment other than pallet forks. Set the steering to the straight ahead position and release the brakes.

3

Raise boom to horizontal position with machine unladen and the inner boom fully retracted.

4

Adjust balance screw B until all lights are extinguished.

During the following procedure, do not raise the load more than 600mm above ground level otherwise the machine may be able to tip forward at a dangerous angle. Keep all personnel clear of the front and rear of the machine. Elec 4-1

1

With boom fully retracted, pick up any load between 1800 and 2000 kg. Use either pallet forks loaded with a test weight or a bucket filled with a high density material.

2

Slowly extend the boom, keeping the load close to the ground, until the machine is balanced about the front axle. Lower the boom to the ground and measure the distance the boom is extended (millimetres).

3

Refer to the chart shown overleaf for the machine concerned and on the scale, find the extension figure measured at step 2 above.

4

Read vertically from the extension figure (example line X) to the Tipping Line AA.

G

5

Read horizontally (example line Y) to the maximum working limit Line BB.

E

6

Read vertically (example line Z) down to the scale and read off the extension figure (example 950 mm).

7

Retract the boom to the extension figure obtained from the chart.

8

Adjust screw F until both amber LEDs D (but not the red LEDs E) are flashing.

9

Fully retract the boom then slowly extend it until the amber LEDs D are flashing. Check the boom is within 20 mm of the figure obtained from the chart.

Note: Some readout boxes have LED H fitted. If LED H is ON, turn screw B anticlockwise until the LED is flashing. If LED H is OFF, turn screw B clockwise until the LED is flashing. LED G is a power-ON indication only.

D

Note: The buzzer will sound when the load exceeds the maximum working limit by 10% and red LEDs E are flashing.

F

B

H S244700

9803/3630

Issue 1


Section C 10 - 5



10 - 5

Calibration - LMI System

1

Park the machine on firm level ground.

The LED indications described are in addition to the green power-on LED G at the bottom of the display, which remains on whenever power is supplied to the display unit.

2

Turn the starter key to the OFF position. Press and hold display button A. Start the engine with button A held down. Hold the button for approximately 30 seconds after the engine has started. All display LEDs will illuminate during this time.

The display unit must be calibrated by setting the ‘100%’ point using a known load and boom extension.

Note: if the button is release during this time, the entire process must be repeated.

! WARNING During the following procedure, do not raise the load more than 600mm above ground level otherwise the machine may be able to tip forward at a dangerous angle. Keep all personnel clear of the front and rear of the machine.

After approximately 30 seconds, the display will show the red LED E only and the alarm will emit short intermittent bleeps. 3

Release button A.

4

With the boom fully retracted, pick up a load between 1800 kg and 2000 kg. Use either pallet forks loaded with a test weight, or a bucket filled with a high density material.

5

Slowly extend the boom. Keep the load close to the ground until the machine is balanced about the front axle with the rear wheels off the ground.

Elec 4-1

Note: If the following actions are not completed within a five minute period, the display will automatically leave the calibration mode and the memory will revert to the previous settings. If the transducer signal is out of range, the display will indicate the appropriate error code. Calibration cannot continue until the fault is rectified.

E D G

100%

6

Press and release the display button A. The display will change to show the amber LED D and red LED E only.

7

Lower the load to the ground and measure the distance the boom is extended.

8

Refer to the correct load chart for the machine (this section).

9

Read up from the extension figure obtained at step 7 (example line X) to the tipping line AA.

10

Read horizontally (example line Y) to the maximum working limit line BB.

11

Read down to the horizontal axis to get the dimension for the boom extension (maximum working limit).

12

Draw a mark on the boom at the dimension obtained above. Raise and retract the boom to the mark drawn on the boom.

13

Press and release the display button. The display will revert to normal operation. The setting of the 100% position is now complete.

A

325920

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics * Safe

11 - 1 * Fault



11 - 1

Finding

The purpose of this section is to help in identifying problems in the system. Once a problem is identified, refer to the test procedures in this section.

FAULT

POSSIBLE CAUSE

Display box does not work.

REMEDY

Blown fuse.

Check fuse 3.

Display box faulty.

Do Display Box Functional Test.

Display box not receiving 12V supply.

Do 12V Supply and Fuse Test.

Transducer not connected.

Check transducer is connected.

Faulty harness.

Check for trapped or damaged wires.

Display box out of calibration (eg) transducer has slipped.

Check display box. Check transducer mounting.

Faulty transducer.

Check for water ingress.

Faulty display box.

Re-calibrate system. Do Display Box Functional Test.

The display box works backwards or seems to be out of calibration. (SLI only)

Display box out of calibration. Transducer may have slipped.

Re-calibrate system. Check transducer mounting.

The display box seems to go out of calibration.

Transducer not fixed down correctly.

Check torque of transducer fixing screws (70Nm). Check transducer fixing screws are not bottoming out in their holes. Check mounting surfaces are clean and flat.

Faulty transducer.

Replace transducer.

Rear axle oscillation trunnions out of alignment (530 only).

Tip machine forward. Check axle oscillates freely. Shim trunnions if required. (T.I. Ref: 5/186; F.136 N. Am)

The display box alarm is sounding and LEDs are continuously illuminated. (SLI only)

9803/3630

Issue 3*


Section C


11 - 2



11 - 2

* Diagnostic Fault Codes - LMI System Only When the system detects a fault, the audible alarm will sound for approximately 10 seconds and various combinations of lights on the display will indicate a fault code. The alarm will cancel after 10 seconds and all the lights on the display will flash as long as the fault remains. Press and release the display button A to show the fault for a further 10 seconds. When the fault clears, the display will return to normal. If any of the fault codes are displayed, switch the starter key off and on again. Refer to the list of fault codes below if the fault does not clear. Note: A new display box will not be calibrated. Always calibrate the system when fitting a new display box.

FAULT CODE

POSSIBLE CAUSE

REMEDY

Fault Code 1

Transducer not connected.

Check transducer connection.

Transducer signal fault

Faulty harness.

Check for trapped or damaged wires.

Faulty transducer.

Check for water ingress. Replace transducer.

Fault Code 2

System is incorrectly calibrated.

Re-calibrate system.

Calibration out of range

Transducer not fixed down correctly.

Check mounting surfaces are clean and flat. Check mounting bolts are not bottoming-out. Check tightness of transducer mounting bolts (70 Nm).

Faulty transducer.

Replace transducer.

System not calibrated.

Calibrate system.

The display box has detected an internal error.

Switch the starter key off and then on again. Replace the display box if the fault does not clear.

Battery voltage is below 9 Volts.

Do 12V supply test at display box. Check battery voltage.

Fault Code 3 Calibration required

Fault Code 4 Display unit faulty

Fault Code 5 Low battery voltage

9803/3630

Issue 4*


Section C


11 - 3



11 - 3

* The following chart is applicable to both the SLI and LMI systems.

System Not Working Correctly. Yes

Do 12V Supply and Fuse Test 1. Record voltage V1. 12V Supply OK ?

Do Harness Wiring Continuity & Short Circuit Test 5. Repair as required. OK Now ?

Yes Done

No No

No

Is the transducer 12V supply OK ?

No

Yes

Check ignition ON, fuse 3, battery condition, test box connections. Repair as required. OK Now ?

Do Transducer 12V Supply Test 2. Record voltage V2. OK Now ?

Yes

Done

Check for uneven mounting surfaces or bolts tightened correctly.

Yes Done

No

Check ignition ON, fuse 3, battery condition, test box connections. Repair as required.

Is the display box OK ?

No

Yes

Do Display Box Functional Test 3 and re-calibrate OK Now ?

Yes Done

No To next page ...

Replace display box.

Are the transducer output signals OK ? Yes

No

Do Transducer Output Tests 4 & 6. Record voltages V3, V4. OK Now ?

Yes Done

No

9803/3630

Issue 4*


Section C


11 - 4



11 - 4

*

Fit new transducer and re-test

... From previous page

No Can the display box be re-calibrated

No

No Do transducer output test OK Now ?

Check transducers fixed securely ?

Yes Yes

Has frequent re-calibration been required ?

Suspect faulty display box. Renew display box OK Now ?

Yes

Possible transducer slipping. Remove transducer, clean surfaces and re-torque bolts to 70Nm OK Now ?

Yes

Yes Done

Yes Done

Suspect faulty transducer

No

Check axle oscillates freely see TI 5/186 (F136 N.Am)

9803/3630

Issue 2*


Section C




11 - 5

11 - 5

G TP1

TP2

TP3

TP4

TP5

RUN

BOSS

TEST 1

CHECK

TRANS

TEST 2

A Power

A244691

B

J

H

100%

244700

F

G

A

325920A

L K 328510

M

328500

9803/3630

Issue 2


Section C


11 - 6


11 - 6

Testing - SLI and LMI Note: The Safe Load Indicator and Load Moment Indicator are not fitted to machines supplied to North America (N. Am).

The test box also contains three switches: TEST 1/TEST 2, TRANS/BOSS, RUN/CHECK to change settings for the various tests.

Introduction

The box is connected between the four-pin plug and socket which connects the readout box to the machine wiring harness behind the instrument panel in the cab.

If the calibration procedure fails to rectify a problem, there are three main areas where faults can occur: the readout box, the transducer, and the machine electrical harness. The test box (892/00905) is designed to assist the service engineer to diagnose faults in the SLI system down to component level. This unit should be used when the standard calibration procedure has been attempted and failed. The test box contains five test points: TP 1 to TP 5 which allow currents in the circuits to be read as voltages by an AVO digital multimeter. The test points also allow continuity and open/short circuit tests to be made. TP1 TP2 TP3 TP4 TP5

Earth Readout box 12V supply Transducer 12V supply Transducer output (Signal) Transducer output (voltage)

Test point TP4 reads signal current in the transducer return wire and converts this to a voltage which can be read by the multimeter.

Before carrying out the tests make sure that: (a) (b) (c) (d)

(e)

the machine is on level ground with the boom horizontal; the forks are fitted, with no load; the boom is fully retracted; two-wheel drive is engaged (if fitted) and the machine has been driven backwards and forwards several times with the wheels in the straight ahead position; the ignition switch is on, but the engine is not running.

Note: The readout display will be affected by extreme steer lock and axle angles. Service Procedure Remove the instrument panel and connect test box A as shown. The BOSS/TRANS switch should be set to the TRANS position for all tests on machines fitted with transducers.

Test point TP5 is a direct connection to the transducer return wire. The Black lead of the multimeter should be connected to TP1 (earth) when testing voltages. Note: When returning equipment under warranty, the results of the following tests MUST be stated.

9803/3630

Issue 2


Section C




11 - 7

11 - 7

Test 1: 12V Supply and Fuse Test (V1) Test box settings:

RUN TRANS TEST 1

V1 TP1 F3 101

Display Box

414

Note: As an additional test, LED C should be illuminated when the display box is receiving a supply voltage.

601

TP2

If the expected reading is not obtained, check the ignition is on, fuse F3, battery condition, test box connections and test harness. Rectify as required.

413

Measure the voltage between TP1 and TP2 Expected reading: Battery voltage (11.0V to 15.0V). 000

1

Transducer 310860

Test 2: Transducer 12V Supply Test (V2)

F3 101

If the expected reading is not obtained, check the ignition is on, fuse F3, battery condition, test box connections and test harness. Rectify as required.

413

Measure the voltage between TP1 and TP3 Expected reading: Battery voltage (11.0V to 15.0V).

414

1

RUN TRANS TEST 1

000

Test box settings:

601

Display Box

TP3

V2

TP1

Transducer

If the expected reading is not obtained after the above checks, the display box should be renewed.

9803/3630

310870

Issue 2


Section C


11 - 8


11 - 8

Test 3: Display Box Functional Test SLI System Only ! WARNING

G

This procedure is ONLY to be used to test that the read out box is functioning, it is NOT to be used to set up the readout box for use on the machine. ELECT 4-2

Test box settings:

CHECK TRANS TEST 1

1

Press test button A and check all warning lights flash and the audible warning operates. If audible warning fails to operate check for visible damage.

2

Turn the display box balance adjuster B until LED H flashes.

3

If LED H is ON, turn adjuster B anticlockwise. If LED H is OFF, turn adjuster B clockwise until the LED is flashing. LED G is ONLY a power-on indication on these display boxes.

4

Switch TEST 1/TEST 2 switch to TEST 2 position.

5

Turn full scale deflection adjuster F until all warning lights and audible warnings just operate. Switch back to the TEST 1 position and check that LED H is still flashing. Note: Adjusters B and F have no end stops. The operating range is 22 full turns from end to end.

A

B F

H S244700

If this test is OK, the display box is functioning correctly. If the above conditions cannot be met, the display box should be renewed.

9803/3630

Issue 2


Section C


11 - 9



11 - 9

Test 3: Display Box Functional Test LMI System Only 1

Park the machine (unloaded) on level ground with the engine running. Apply the parking brake and place the forward/reverse lever in the neutral position.

2

The green LED G at the bottom of the display will illuminate to show that the indicator is receiving power.

3

Press the display button A and release.

4

All LEDs on the indicator will flash and the audible alarm will sound if the unit is functioning correctly.

100%

G A

325920A

9803/3630

Issue 2


Section C




11 - 10

11 - 10

Test 4: Transducer Output Test (V3) (Transducer Fitted)

F3 101

Measure the voltage between TP1 and TP4 Expected reading: 4.3V to 4.7V.

413

Display Box

414

1

RUN TRANS TEST 1

000

Test box settings:

601

TP4 If the expected reading is not obtained, carry out Test 5 to check for possible harness faults.

Transducer

If Test 5 is successful, a transducer fault or incorrect transducer mounting should be suspected. Carry out Test 6 to test transducer output with the transducer removed from the axle.

V3

TP1

310880

Test 5: Harness Wiring Continuity And Short Circuit Test Test box settings:

1

2

CHECK TRANS TEST 1

Disconnect the display box from the test box harness K, but leave the Test box harness connected to the machine wiring L. Disconnect the transducer harness from the machine wiring M. Turn OFF the ignition switch and check for continuity between the following points on the test box and the two pin connector E that was connected to the transducer. Remove the plastic pin retainer on the plug to access the connections.

If the expected readings are not obtained, check for damaged wiring and faulty connections. If the expected readings are obtained, but the expected voltage reading from Test 4 above is not achieved, carry out Test 6 with the transducer removed from the axle.

Continuity Test 3

Switch the multimeter to the Ohms scale and measure the electrical resistance between: TP3 and pin 2 of connector M. TP5 and pin 1 of connector M. Expected reading: Less than 3 ohms. Short Circuit Test

4

Measure the electrical resistance between: TP1 and TP5 TP1 and TP3 TP3 AND TP5 Expected reading: Open Circuit.

9803/3630

Issue 2


Section C


11 - 11



11 - 11

Test 6: Transducer Output Test (V4) (Transducer Removed)

F3 101

Reconnect the battery and turn the starter switch to on, but with the engine not running.

3

Reconnect the display box to the test harness.

413

2

601

Display Box

414

Remove the transducer from the machine, reconnect to the machine harness and support under the machine.

000

1

TP4 Test box settings:

RUN TRANS TEST 1

Transducer V4

4

TP1

Measure the voltage between TP1 and TP4 Expected reading: 4.48V to 4.52V. 310890

If the transducer is not distorted, then V4 should be between 4.48V and 4.52V. If it is outside this range, but within 4.40V to 4.60V, it may still be OK providing that the conditions of Test 4 are achieved. If the transducer passes this test, having failed Test 4, the apparent failure is probably due to uneven transducer mounting. Check mounting surfaces are clean, flat and free from paint and rust etc. Refit the transducer to the machine and tighten the transducer fixing screw to 70Nm. Remove the test harness and reconnect electrical plugs.

9803/3630

Issue 1


Section C


11 - 12


11 - 12

Voltage Readings The following table may be used to record information in the event of an enquiry and must be submitted together with a warranty claim. If applicable any warranty parts must also be returned with any additional information such as: which lights are not illuminating, if system balancing is possible, or if display box function test is not successful. Expected Readings

V1 V2 V3 V4

V1

11.0V to 15.0V

V2

11.0V to 15.0V

V3

4.3V to 4.7V

V4

4.48V to 4.52V

Measured Readings

12V Supply Transducer supply voltage Transducer output voltage (Fitted) Transducer output voltage (Removed)

IMPORTANT: The system must always be re-calibrated after performing the above tests, and before operating the machine.

9803/3630

Issue 1


Section C

www.WorkshopManuals.co.uk Electrics Transducer

12 - 1


12 - 1

Removal

Replacement

Carry out General Safety procedures. See Machine Safety (Section 3).

1

Remove any old sealant, rust dirt or paint from the mounting faces on the axle.

! WARNING

2

Make sure that the mounting faces are flat, level and free of burrs.

3

Apply JCB High Strength Retainer (4101/0651) to the mounting faces. Fit foam pads F and G.

4

Position transducer E as shown. Check the bolt holes align and the mating faces are flush.

5

Secure the transducer with spacers D and bolts C. Coat the bolts with JCB Threadlocker and Sealer (4101/0251) and tighten evenly to 70 Nm.

6

Apply silicone sealant (4102/0901) to the heads of the bolts and spacers and fit protective caps B.

7

Connect electrical harness A. Make sure the cable to the transducer is secure to prevent damage from movement of the trackrod and away from the axle oscillation stops.

8

Calibrate the system.

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

Raise the rear end of the machine, under the chassis, until the rear wheels are clear of the ground. Note: Do not lift the machine from under the axle.

2

Remove a road wheel, angle and support the axle to gain access.

3

Disconnect the electrical harness at A.

4

Remove plastic caps B, bolts C, spacers D, transducer E and foam pads F and G.

Torque Settings Item C

A

Nm 70

kgf m 7.1

lbf ft 51.6

B C D E F G

327720

9803/3630

Issue 4*


Section C



Parking Brake Switch

13 - 1

13 - 1

Adjustment 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 1 in a clockwise direction until the audible alarm sounds and the visual warning is illuminated.

1 2

* Screw the switch a further half turn and lock switch 1 in position with lock nut 2. 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.

S193440

9803/3630

Issue 2


Section C

www.WorkshopManuals.co.uk Electrics Proximity Switches

14 - 1


14 - 1

* Adjustment 1

Align the wheels in the straight ahead position. Check by measuring the steering ram position, as shown. Set the steering so that dimension X is 129mm.

2

Remove the proximity switch cover (rear sensor only). Position the proximity switch D directly below the target disk E on the track rod.

3

With the ignition switch on, adjust the proximity switch until the LED on the cable end of the switch illuminates.

4

Advance the proximity switch a further 1/2 to 3/4 of a turn towards the washer, then tighten locknuts F.

E F F D

X

A279920

300710

*

Front

Rear

331310

9803/3630

331320

Issue 4*




www.maskinisten.net

Section C



Electronic Control Unit (ECU) - Four Speed Transmission

15 - 1

General Description

15 - 1

ECU Mounting

The ECU was introduced in January 1997, and was superseded in May 1997 by the improved Mark 2 unit, and by the Mark 3 unit in June 1997, on machines up to serial number 770093. The ECU function was replaced by relays after machine serial number 770093. ECU control was re-introduced with the five speed Powershift transmission in February 2001. See Electronic Control Unit (ECU) - Five Speed Transmission (this section). The Electronic Control Unit (ECU) is designed to control the selection of gears and direction. The unit is microprocessor controlled and is mounted over the transmission solenoid valves. A cable harness connects the ECU to the solenoids, the gearbox oil pressure switch and a speed sensor. The chassis mainframe harness connects the unit to various switches and selectors in the cab.

The early Mark 1 unit can be identified by the four mounting screws A passing through the casing. The Mark 2 and 3 units dispensed with the mounting holes and were attached using mounting brackets and screws, as shown at B. The Mark 3 unit was removed from Loadall machines in September 1997 and replaced by relay control. IMPORTANT - When installing an ECU, tighten the mounting screws hand tight only (1Nm) and use JCB Threadlocker and Sealer on the threads. Overtightening the mounting screws can damage the ECU and internal components. Mark 1 ECU

A A

The ECU receives signals from the gear/direction selector and other switches in the cab and operates the appropriate transmission solenoids accordingly. Built-in software prevents potentially damaging (and inappropriate) clutch pack selections being made.

A A

The ECU software incorporates a ‘Fourth Gear Inhibit’ (Germany only). Each ECU is factory configured and is not transferable between transmission variants.

A372360

ECU Replacement It is important that a replacement ECU is correct for the model of machine. Two types of ECU are available, as shown below: 4 Speed

-

530

3 Speed

-

530

Mark 2 and 3 ECU

(Germany only)

Note: The version of the software shown on the label of an ECU should not be used for identification purposes.

B

B

299410

9803/3630

Issue 4*


Section C


16 - 1



16 - 1

Fault Finding Electrical problems with the ECU can be easily diagnosed by the use of a multi-meter or test lamp. Alternatively, the Hand Held Test Unit A (Part Number 892/00943) can be used. The test unit has the advantage of being able to monitor the ECU functions from inside the cab.

A

General Fault Finding Refer to the Fault Finding Guide in this section to identify possible problem areas. When a suspected ECU problem is encountered, the following basic checks should be performed before checking major system components. 1

Check the ECU Fuse 14.

2

Check the condition and security of the ECU connectors.

3

Check the condition of the rubber seal in the ECU harness connectors.

Note: The ECU is not affected by the low pressure switch or two/four wheel drive circuits.

299920

Intermittent Faults If a fault appears to be intermittent (eg. transmission dropping to neutral), select a gear and place small washers on the ends of the energized solenoids - the washers will be held in place by the magnetic attraction. Drive the machine without changing gear or direction. If a fault appears, examine the washers. If one or both of the washers has dropped off, this indicates an electrical fault. Examine the wiring harness and ECU. If both washers are in place, the problem may be in the transmission.

Diagnostic Tips and Warning Information Machine Harnesses 1

NEVER check for voltages directly across any pins on the ECU. Internal damage can result from shorting pins.

2

ALWAYS ensure the machine ignition is switched off before connecting or disconnecting the ECU or test unit.

3

After using the test unit, ALWAYS ensure the diagnostic tool connecting lead blanking plug is replaced to prevent corrosion or water ingress into the connector.

4

In the event of a bad input connection from the mainframe harness, the ECU will select either neutral or the last selected gear in the same direction for a short period. This will prevent the machine becoming stranded in traffic conditions.

5

Tighten the ECU mounting screws hand tight only (1Nm) and use JCB Threadlocker and Sealer. Overtightening the mounting screws can damage the ECU and internal components.

6

Ensure the ECU is connected the correct way round.

Machine harness faults are a common source of ECU inoperability. The integrity of the electrical connectors and components is important for fault-free operation. Moisture or contamination trapped in the connectors when re-assembled is a probable cause of many faults. This will eventually damage the terminal pins. To prevent against connector terminal corrosion, it is recommended that a water dispersant spray is used on assembly. Electrical connectors cannot be expected to sustain direct steam cleaning using high pressure hoses. It is recommended that operators make themselves aware of connectors which are vulnerable to a direct jet from a steam cleaner and avoid continuous contact. A damaged harness can send false signals to the ECU and problems will occur. Poor earthing can also cause problems - ensure the earths to the ECU and switches are secure.

9803/3630

Issue 2*


Section C


16 - 2



16 - 2

Checking Solenoid Operation

Checking for (+ve) Supply to the Solenoids

For each first and second gear selections, two solenoids will be energized. For each third and fourth gear selections, only one solenoid will be energized.

The following test should be carried out with the park brake in the OFF position (see 3).

Correct operation of the solenoids can be confirmed as follows: 1

Chock the roadwheels and remove Fuse 12 to prevent the engine starting.

2

Release the parkbrake and switch the ignition ON.

3

Identify the correct two solenoids for each gear selection using the table below.

4

Select forward first gear on the gear selection switch.

5

Check for a magnetic attraction on the ends of the solenoids C and D using a screwdriver or feeler gauges. Ensure that no other solenoids are energized.

6

If the solenoids are not energized, check the solenoids are receiving a power supply (see next section).

7

If the wrong solenoids are energized, check the connectors are attached to the correct solenoids.

8

If the solenoids are energizing correctly, the transmission may be faulty. Refer to the Transmission Section for fault finding information.

9

1

Remove Fuse 12 to prevent the engine starting.

2

Chock the road wheels to prevent the machine moving.

3

Release the parkbrake and switch ON the ignition.

4

Select forward first gear at the gear selection switch.

5

Identify solenoids C and D, remove each electrical connector in turn and check for a voltage across the two terminals using a test lamp or multi-meter.

6

Repeat the test for all gear selections.

Note: If a voltmeter is used for this test, it should be noted that a reading less than battery voltage (typically 5-9V) will be recorded with the solenoid disconnected. This should not be interpreted as a fault.

Solenoid Identification A B C D E F

Forward High Reverse Low Forward Low Layshaft (Mainshaft) Reverse High 2/4 Wheel drive

G Speed Sensor Connector H Pressure Switch Connector J Mainframe Harness Connector

Repeat the test for all gears selections.

Note: The layshaft/mainshaft solenoid D is energized in the layshaft position and is spring loaded to the mainshaft position. When third or fourth gear is selected, the solenoid will not be energized.

F

A Forward Gears

Reverse Gears

B

1st

Forward Low and Layshaft

C/D

Reverse Low and Layshaft

B/D

2nd

Forward High and Layshaft

A/D

Reverse High and Layshaft

E/D

Forward Low and Mainshaft

C

Reverse Low and Mainshaft

B

Forward High and Mainshaft

A

Reverse High and Mainshaft

E

3rd

4th

C

J D

E

G H 9803/3630

A372360

Issue 2*


Section C 16 - 3




16 - 3

Checking the Mainframe Harness Note: the following checks should be carried out with the park brake in the in the OFF position.

Mainframe Harness Connector Plug Voltage Readings: FORWARD GEARS

1

Chock the road wheels.

2


3

Release the parkbrake.

4

Clean the area around the mainframe harness connection to the ECU and remove the connector.

5

Check the condition of the connector and socket. Check the condition of the rubber seal in the mainframe harness connector.

6

Switch ON the ignition, select a gear and, with the help of an assistant, hold the transmission dump button in the ON position. Check for battery voltage on the pins of the harness connector using pin 16 as an earth. Refer to the following table to identify the correct pins for each gear selection.

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

F1 Y Y Y Y Y Y Y

F2 Y Y Y Y Y Y Y

F3 Y Y Y Y Y Y Y

F4 Y Y Y Y Y Y Y Y

R3 Y Y Y Y Y Y Y

R4 Y Y Y Y Y Y Y Y

REVERSE GEARS 7

If the lamp illuminates where indicated (Y), the integrity of the harness, switches and power supply to the ECU is proven.

Note: Depending on machine specification, there may be no electrical connections to pins 6, 8, 11 and 14.

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

R1 Y Y Y Y Y Y Y

R2 Y Y Y Y Y Y Y

Note: the ECU is powered by pins 17 and 18 (+V) and earthed by pins 15 and 16. 299230

9803/3630

Issue 2*


Section C 16 - 4




16 - 4

Checking the Park Brake Switch

Checking the Transmission Dump Switch

1

Chock the road wheels and remove Fuse 12 to prevent the engine starting.

7

Check for a voltage across pin 9 and pin 16 of the mainframe harness connector using a voltmeter.

2

Select a forward or reverse gear and apply the park brake.

8

With the help of an assistant, operate the transmission dump button.

3

Switch ON the ignition.

9

4

Check for a voltage across pin 18 and pin 5 of the mainframe harness connector using a voltmeter or test lamp.

There should be 12V detected when the transmission dump button is pressed, and zero volts when the transmission dump button is released.

5

With the help of an assistant, release the park brake.

6

There should be 12V detected with the park brake in the ON position and zero volts with the park brake in the OFF position.

299160

9803/3630

299170

Issue 2*


Section C




17 - 1

17 - 1

Simplified ECU Installation

600CB

600BT

Mainframe Harness Side

Pin No.

Pin No.

A A

R

F

600CA

12

17

852

6

2

811

11

1

849

15

4

812

16

3

848

5

5

850

600BS

600BX

600BY

13

6

9

16

600TE

Z

7

8

110

1

11

982

5

1

C C

ECU 14

13

981

4

17

14

980

3

18

18

405

8

15

600BU

2

4

9

600Y

3 4

10

10

600Z

1

2

7

109H

3

3

12

974

2

+12V DC

D

D

1

B

300120

B

Mainframe Connections:

Transmission Connections:

Main Components:

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

1 2 3 4 5

A B C D E

Forward Third gear Fourth gear First gear Handbrake N/A Reverse gear N/A Transmission Dump Second gear Spare earth N/A Low pressure switch Four wheel drive (optional) Earth Earth + 12V + 12V

6 7 8 9 10 11 12 13 14 15 16 17 18

Reverse Low solenoid Reverse High solenoid Forward Low solenoid Forward High solenoid Layshaft and Mainshaft solenoid N/A Speed sensor (+VE) Test unit (+VE) Earth Earth Test unit Signal - speed sensor Test unit Test unit Earth - Low pressure switch Earth - test unit Four wheel drive solenoid Low pressure switch

9803/3630

E E

Forward/Reverse Lever Gear Selection Switch Test Unit Low Pressure Switch Speed Sensor

Issue 5*


Section C


17 - 2



Handheld Mark II Test Unit

5

After a short time, the test unit will then show the ECU ‘Setting Screen’. The unit holds this screen until any of the keys on the keypad are pressed.

This section describes how to use the Mark II handheld test unit for electrical fault diagnosis on ECU controlled powershift transmissions. The information refers only to the Mark II test unit (892/00943). Mark 1 test units (460/33000) should be upgraded to the improved version. Never connect or disconnect a mark 1 test unit with the ignition switched ON or the ECU and test unit can be damaged. Mark II test units have internal protection.

17 - 2

This screen allows the operator to check that the software settings in the ECU are correct for the ECU part number and application. 6

After pressing any key, the test unit then moves to the Diagnostic Screen.

IMPORTANT - If you intend to use the test unit while the machine is in motion you must take all recautions to ensure the safety of yourself and others. Do not use the test equipment on a public highway.

Gear Selector Inputs

Operating Instructions 1

2

Switch Inputs

Switch OFF the ignition. Locate the diagnostic connector on the gearbox harness and remove the blanking plug.

Switch ON the ignition to power the transmission ECU, which will supply power to the test unit.

4

A ‘Title Screen’ will be shown on the display for a period of approximately five seconds. This allows the operator to determine the type of test unit in use. 460/33000 892/00943

Mark One test Mark Two test unt

T e s t P t

N o

unit

U n i t

ECU Output

This allows the opeator to view inputs into the ECU and the gear being selected on the selector swtich.

Connect the test unit 6-pin mating plug to the diagnostic connector and ensure that the test unit end of the connection cable is securely attached.

3

Speed Input

Using the example shown above, the diagnostic screen contains: 1 2 3 4

Selected Gear

F R

Selected Direction

H

Handbrake Switch ON/OFF

K

Kickdown ON/OFF (including gear - e.g. K2)

D

Transmission Dump Switch ON/OFF

252

Speed Signal (of Transfer Gear in Hz)

R4

ECU Output

V 3 . 0 0

8 9 2 / 0 0 9 4 3

A372370

9803/3630

Issue 2*


Section C




17 - 3

17 - 3

The speed sensor sends a pulse to the ECU for each tooth on the output transfer gear. The freqency of these pulses is the value displayed. Note: it is possible to relate this value to the road speed, if the axle ratio and rolling radius are known. The ECU output shows the direction and gear that the ECU is sending to the gearbox solenoids. ie.

F 1 = Forward 1st R 2 = Reverse 2nd N = Neutral

Operating the various controls in the cab will change the display accordingly. Some examples can be seen below.

EXAMPLE 1: This shows that the input selection is 2nd gear [2] and forward direction [F]. However, because the handbrake is applied [H] the transmission is held in neutral [N].

0

EXAMPLE 2: This example shows the input selection is 2nd gear [2] and forward direction [F]. The kickdown input [K] (if fitted) is also active and so the ECU has selected the next lowest gear, ie. forward 1st [F1]. EXAMPLE 3: This example shows the input selection is 2nd gear [2] and forward direction [F]. However, because the transmission dump button [D] has been pressed, the ECU holds the gearbox in neutral [N] until the button is released.

*

0

ECU Factory Default Settings The default settings for the range of ECU’s fitted to Loadalls, are shown in the table below. ECU Part No.

Machine

449/03806

530, 3 speed

4000

5000

449/03805

530, 4 speed

4000

5000

449/03807

530, 4 speed (18/36 way ECU)

N/A

N/A

Note: 1 2 3 *

Downshift Hz 2-1 3-2 4-3

Kickdown Seconds

1

Gear Lever 2 3 4

6000

6

2

4

8

6000

6

2

4

8

N/A

6

2

4

8

Type

Label Colour

45

JCB

Orange

40

JCB

Purple

40

JCB

None stated

18/36 WAY ECU fitted to very early machines without speed sensor. Downshift figure 4000 and above disable downshift protection. “4” = 45 means 4th Gear inhibited (Germany only).

9803/3630

Issue 2*


Section C 18 - 1

www.WorkshopManuals.co.uk Electrics Electronic Control Unit (ECU) - Five Speed Transmission


18 - 1

General Description

Five Speed Operation

ECU control was re-introduced with the five speed Powershift transmission in February 2001. The transmission incorporates an ‘autoshift’ feature which will automatically change up from 4th gear to 5th gear when a pre-set road speed is reached. Manual 1st, 2nd and 3rd gears are available for on-site work. Fifth gear is not available in reverse.

Two modes of operation are available. Automatic operation is selected via the forward/reverse lever rotary switch position 4, and manual operation by selecting position 1, 2 or 3 as required.

The 18/36 pin ECU A is microprocessor controlled and is mounted under the driver’s seat. A cable harness connects the ECU to the solenoids, the gearbox oil pressure switch and a speed sensor. The panel harness connects the unit to various switches and selectors in the cab. The ECU receives signals from the gear/direction selector and other switches in the cab and operates the appropriate transmission solenoids accordingly. Built-in software prevents inappropriate (and potentially damaging) clutch pack selections being made.

Automatic Operation The transmission will change gear automatically according to road speed. This mode is recommended for road travel only. Switch to manual operation for on-site work. Manual Operation 1st, 2nd and 3rd gears are selected normally on the steering column switch. The ECU will not allow downshifts above a certain speed. Two audible bleeps will sound and the transmission will remain in the currently selected gear until the speed has reduced sufficiently.

ECU Replacement Each ECU is factory configured and is not transferable between transmission variants. It is important that a replacement ECU is correct for the model of machine. Note: The version of the software shown on the label of an ECU should not be used for identification purposes.

A

A372800

9803/3630

Issue 2*


Section C


18 - 2

Electronic Control Unit (ECU) - Five Speed Transmission


18 - 2

Fault Finding

Intermittent Faults

Electrical problems with the ECU can be easily diagnosed by the use of a multi-meter or test lamp. Alternatively, a portable computer with the appropriate software and communications cable (892/00952) can be used. See Using the PC Diagnostic Tool (this section).

If a fault appears to be intermittent (eg. transmission dropping to neutral), select a gear and place small washers on the ends of the energized solenoids - the washers will be held in place by the magnetic attraction.

General Fault Finding Refer to the Fault Finding Guide in this section to identify possible problem areas. When a suspected ECU problem is encountered, the following basic checks should be performed before checking major system components. 1

Check the ECU Fuse 14.

2

Check the condition and security of the ECU connectors.

3

Check the condition of the rubber seal in the ECU harness connectors.

Note: The ECU is not affected by the low pressure switch or two/four wheel drive circuits. Diagnostic Tips and Warning Information 1

NEVER check for voltages directly across any pins on the ECU. Internal damage can result from shorting pins.

2

ALWAYS ensure the machine ignition is switched off before connecting or disconnecting the ECU or test unit.

3

After using the test unit, ALWAYS ensure the diagnostic tool connecting lead blanking plug is replaced to prevent damage to the connector.

4

In the event of a bad input connection from the mainframe harness, the ECU will select either neutral or the last selected gear in the same direction for a short period. This will prevent the machine becoming stranded in traffic conditions.

Drive the machine without changing gear or direction. If a fault appears, examine the washers. If one or both of the washers has dropped off, this indicates an electrical fault. Examine the wiring harness and ECU. If both washers are in place, the problem may be in the transmission. Machine Harnesses Machine harness faults are a common source of ECU inoperability. The integrity of the electrical connectors and components is important for fault-free operation. Moisture or contamination trapped in the connectors when re-assembled is a probable cause of many faults. This will eventually damage the terminal pins. Electrical connectors cannot be expected to sustain direct steam cleaning using high pressure hoses. It is recommended that operators make themselves aware of connectors which are vulnerable to a direct jet from a steam cleaner and avoid continuous contact. A damaged harness can send false signals to the ECU and problems will occur. Poor earthing can also cause problems. Ensure the earths to the ECU and switches are secure.

9803/3630

Issue 4*


Section C


18 - 3



Correct operation of the solenoids can be confirmed as follows: 1

Chock the roadwheels and remove Fuse 12 to prevent the engine starting.

2

Release the parkbrake and switch the ignition ON.

3

Identify the correct two solenoids for each gear selection using the table below.

4

Select forward first gear on the gear selection switch.

5

Check for a magnetic attraction on the ends of the solenoids D and E using a screwdriver or feeler gauges. Ensure that no other solenoids are energized.

7

If the solenoids are not energized, check the solenoids are receiving a power supply (see next section). If the wrong solenoids are energized, check the connectors are attached to the correct solenoids.

8

If the solenoids are energizing correctly, the transmission may be faulty. Refer to the Transmission Section for fault finding information.

9

Repeat the test for all gears selections.

Forward Gears

18 - 3

Checking for (+ve) Supply to the Solenoids

For each of the gear selections, two solenoids will be energized.

6


The following test should be carried out with the park brake in the OFF position (see Step 3). 1


2

Chock the road wheels to prevent the machine moving.

3

Release the parkbrake and switch ON the ignition.

4

Select forward first gear at the gear selection switch.

5

Identify solenoids D and E, remove each electrical connector in turn and check for a voltage across the two terminals using a test lamp or multi-meter.

6

Repeat the test for all gear selections.

Note: If a voltmeter is used for this test, it should be noted that a reading less than battery voltage (typically 5-9V) will be recorded with the solenoid disconnected. This should not be interpreted as a fault.

Solenoid Identification A B C D E F G H

Forward High Mainshaft Reverse Low Forward Low Layshaft Reverse High 2/4 Wheel drive 5th Gear

Reverse Gears

1st

Forward Low and Layshaft

D/E

Reverse Low and Layshaft

C/E

2nd

Forward High and Layshaft

A/E

Reverse High and Layshaft

E/F

3rd

Forward Low and Mainshaft

D/B

Reverse Low and Mainshaft

B/C

4th

Forward High and Mainshaft

A/B

Reverse High and Mainshaft

B/F

5th

Mainshaft and 5th Gear

B/H

H A

D

G B

E

C

F

S296931

9803/3630

Issue 1


Section C




18 - 4

18 - 4

Checking the Mainframe Harness Note: the following checks should be carried out with the park brake in the in the OFF position. 1

Chock the road wheels.

2


3

Release the parkbrake.

4

Clean the area around the mainframe harness connection to the ECU and remove the connector.

5

Check the condition of the connector and socket. Check the condition of the rubber seal in the mainframe harness connector.

6

Check for battery voltage on the pins of the harness connector using pin 12 as an earth. Refer to the following table to identify the correct pins for each gear selection.

7

If the lamp illuminates where indicated (Y), the integrity of the harness, switches and power supply to the ECU is proven.

Mainframe Harness Connector Plug Voltage Readings: FORWARD GEARS PIN 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

F1 * Y Y Y Y -

F2 * Y Y Y Y -

F3 * Y Y Y Y -

F4 * Y Y Y Y Y -

Remarks

*12V present only when throttle pressed Reverse 4th gear 2nd gear Parkbrake Warning buzzer output Ground Ground Transmission low pressure output 3rd gear Forward Transmission dump 1st gear Neutral

12V feed 12V feed PC diagnostic socket PC diagnostic socket PC diagnostic socket PC diagnostic socket Speed output

9803/3630

Issue 1


Section C




18 - 5

18 - 5

Checking the Mainframe Harness (continued) Mainframe Harness Connector Plug Voltage Readings: REVERSE GEARS PIN 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

R1 * Y Y Y Y -

R2 * Y Y Y Y -

12 11 10 9

R3 * Y Y Y Y -

8

R4 * Y Y Y Y Y -

7

6

5

4

Remarks

*12V present only when throttle pressed Reverse 4th gear 2nd gear Parkbrake Warning buzzer output Ground Ground Transmission low pressure output 3rd gear Forward Transmission dump 1st gear Neutral

12V feed 12V feed PC diagnostic socket PC diagnostic socket PC diagnostic socket PC diagnostic socket Speed output

3

2

1

24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25

A372660

9803/3630

Issue 1


Section C




18 - 6

18 - 6

Checking the Park Brake Switch

Checking the Transmission Dump Switch

1

Chock the road wheels and remove Fuse 12 to prevent the engine starting.

7

Check for a voltage across pin 24 and pin 17 of the mainframe harness connector using a voltmeter.

2

Select a forward or reverse gear and apply the park brake.

8

With the help of an assistant, operate the transmission dump button.

3

Switch ON the ignition.

9

4

Check for a voltage across pin 24 and pin 8 of the mainframe harness connector using a voltmeter or test lamp.

There should be 12V detected when the transmission dump button is pressed, and zero volts when the transmission dump button is released.

5

With the help of an assistant, release the park brake.

6

There should be 12V detected with the park brake in the ON position and zero volts with the park brake in the OFF position.

V

V

-

24 12 11 10 9

17

24

8 7

6

5

4

3

2

1

23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25

12 11 10 9

8

7

6

23 22 21 20 19 18

5

4

3

2

1

16 15 14 13

36 35 34 33 32 31 30 29 28 27 26 25

A372630

9803/3630

A372640

Issue 1


Section C




18 - 7

18 - 7

Simplified ECU Installation

SPEED GROUND GROUND

PARKBRAKE BUZZER LOW PRESSURE DUMP

THROTTLE

+12V

FEED +12V FEED +12V

A

REVERSE R

NEUTRAL

N

FORWARD

F

GEAR 1

1

B

2

GEAR 2

3

GEAR 3

4

C

PC SOFTWARE TOOL

GEAR 4 RS232: GND

3

RS232: RX

1

RS232: TX

2

RS232: CTS

4

1 10 29 11 12 35 36 8 9 13 17 2 14 3 23 24 6 4 20 16 18 7 15 5 25 26 27 28

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

SOLENOID (5TH)

SOLENOID (RL) SOLENOID (RH) SOLENOID (FL) SOLENOID (FH) SOLENOID (LS) SOLENOID (MS)

1 FEED (S.SENSOR) S.SIGNAL - INPUT

3

SPEED SENSOR

E

2

LOW OIL PRESS SWITCH EARTH (SPEED SENSOR)

D A372391

POWERSHIFT ECU 728/16200

Mainframe Connections 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

Input: Throttle switch Input: Reverse switch Input: Fourth gear switch Input: Second gear switch Input: Parking brake switch Output: Buzzer Earth Earth Output: Low pressure switch Input: Third gear Input: Forward drive switch Input: Transmission dump Input: First gear Input: Neutral switch

+12V Feed +12V Feed RS232: Earth RS232: RX

27 RS232: TX 28 RS232: CTS 29 Output: Speed 30 31 32 33 34 35 36 Transmission Connections

15 Earth: Speed sensor 16 17 18 Low oil pressure switch Main Components A B C D E

Forward/Reverse switch Gear selection switch Diagnostic software tool Low pressure switch Speed sensor

1 Solenoid: Reverse low 2 Solenoid: Reverse high 3 Solenoid: Forward low 4 Solenoid: Forward high 5 Solenoid: Layshaft 6 Solenoid: Mainshaft 7 +12V Speed sensor feed 8 Solenoid: Fifth gear 9 10 11 12 Speed sensor signal 13 14

9803/3630

Issue 1


Section C 18 - 8

www.WorkshopManuals.co.uk Electrics Electronic Control Unit (ECU) - Five Speed Transmission


18 - 8

Using the PC Diagnostic Tool The diagnostic software is intended for use on IBM compatible personal computers using Windows 95 or later. The software is not compatible with Windows 3.x or Windows NT. Details of software installation and operation are provided * with the software. The software is available on Disk 3 of the Technical Information, Parts and Service CD-Rom from Issue 18 in English only. The computer is connected to the diagnostic socket on the ECU via communications cable (892/00952). The ECU diagnostic software consists of four screens. Before entering the diagnostic screens, the correct drivetrain options must be input using the 'Speed Options' function under the 'File' menu. If the incorrect settings are used then the output figures from the software will be incorrect.

A

A372800

The tool provides a real time display of the following information: -

ECU factory settings and information System status Solenoid identification Solenoid testing

Operation ! WARNING Do not check the ECU while the machine is moving. This can result in injury or death. Take all necessary steps to ensure the safety of yourself and others. 0055

1

Connect the 9-pin D-type connector of the communication cable to the serial port on the computer.

2

Connect the other end of the cable to the diagnostic socket A on the ECU. Note: The cable may be fitted with two different types of connector. The Sumitomo type connector is for use with JCB machines.

3

Turn the starter switch to the IGN position. Do not start the engine. The display shows the current status of the ECU. An appropriate error message is displayed if the software is not communicating with the ECU, or if a fault is detected in the solenoids or wiring.

9803/3630

Issue 2*


Section C


18 - 9



18 - 9

ECU Diagnostic Screens 1

The 'Scan Solenoids' button at the bottom of the screen is used to check the integrity of the solenoids and the connections to them. When this function is selected, any electrical faults in these areas will be highlighted.

ECU Settings and Information The ECU Settings and Information screen gives information about the current settings of the ECU. Factory settings are as detailed below. Setting * Reverse 2-1 3-2 4-3 5-4 4-5 Gear 1 Gear 2 Gear 3 Gear4 Kickdown time Oil delay † Inhibit 4WD above gear † Invert 4WD output Antistall

Units

Value

Hz Hz Hz Hz Hz Hz Integer Integer Integer Integer secs secs Integer Yes/no Hz x 10

1772 360 635 800 1350 1446 1 2 4 12 6 0.2 4 No 130

3

Solenoid Identification The Solenoid Identification screen gives a pictorial view of the transmission solenoids for identification purposes.

4

Solenoid Testing The Solenoid Testing screen provides the ability to energise the transmission solenoids individually for use when pressure testing individual clutch packs. The park brake must be applied and the machine in neutral before the solenoids can be energised. Selecting a particular solenoid on the screen will allow the operator to energise the corresponding clutch pack on the machine.

† These settings have been developed to optimise machine performance and cannot be modified. Although incorporated in the ECU software, the 2/4 WD circuit is not affected by the ECU. 2

System Status The System Status screen provides information about the current status of both the inputs and the outputs of the ECU. Lever status:

This shows the gear and direction currently selected on the input lever.

Throttle switch:

This shows a positive signal when the throttle pedal is pressed.

Parkbrake:

This shows a positive signal when the park brake is engaged.

Low oil pressure:

This indicates when the transmission oil pressure switch senses a low pressure.

Dump:

This shows a positive signal when the transmission dump button is pressed

The screen will also show battery voltage, selected gear output to the solenoids (as distinct from lever input), and speed sensor reading. Note: The machine will not change into 4th gear until the speed sensor sees a signal.

9803/3630

Issue 2*


Section C



Speed Sensor

19 - 1

19 - 1

Checking Speed Sensor Operation Machines equipped with a transmission ECU have a speed sensor A fitted. The sensor detects the speed of rotation of the output shaft and sends this information to the ECU.

TA

B

The ECU requires a speed signal to determine the operating speed of the machine. Some gear selections will not be permitted if the speed signal is too high (ie. downshifts).

A

TB

Note: the ECU is designed to inhibit 4th gear selection if the speed sensor fails to send a signal. Test lamp (892/00940) should be used to check the operation of the speed sensor, as follows:

1

Park the machine on firm level ground, engage the parking brake and set the forward/reverse lever to the neutral position.

2

Switch off the engine and remove the starter key.

3

Connect the test lamp B, as shown. Secure the wires clear of the driveshaft and other moving parts, in a position where the light emitting diode (LED) can be clearly seen.

4

Start the engine, and drive the machine forward approximately five feet; alternatively, raise the wheels off the ground.

5

If the sensor is operating correctly the LED will illuminate when a gear tooth passes the sender. As the speed increases the lamp will flash, lighting continually at high speeds.

6

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

7

Switch the ignition ON. Place a metal object such as a spanner against the sensor and check if the LED illuminates.

8

If the LED illuminates, the sensor gap is too large. Check the correct spacer is fitted. See Section F Transmission - Powershift Assembly for details of speed sensor depth adjustement.

308630

Note: Speed sensors generally do not fail electrically. Most problems are caused by physical damage or incorrect installation. If fourth gear cannot be selected, and drive is re-established when the test lamp is connected, the ECU should be renewed due to an internal fault. Sensor Connections: 1 2 3

Brown Blue Red

3

Check for sensor damage.

b)

Check correct spacer is fitted.

c)

Check for battery voltage at harness pin 1 and an earth at pin 3. If the pins in the harness are OK, fit a new sensor and re-check. If the fault is still apparent, carry out a continuity check between the connector and the ECU.

1

600 109

If the LED does not illuminate, the following checks should be performed: a)

2

974 A364310

Repair or replace the harness as required.

9803/3630

Issue 1


Section C



Speed Sensor

19 - 2

19 - 2

Fault Finding Guide 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 as this section deals with the mechanical aspects. 1

Before you begin fault finding, read the Safety Information at the beginning of this manual.

2

Make simple checks before stripping a major component.

3

Make any relevant electrical checks before commencing work.

POSSIBLE CAUSE

FAULT

REMEDY

Machine will not start

Forward/reverse lever not in neutral

Place forward/reverse lever in neutral before starting the engine (machines with neutral start relay only).

No drive.

Attempting to select drive with the park brake engaged.

Release park brake

Blown ECU fuse.

Check ECU fuse 14

ECU mainframe connector loose.

Check connector is mating correctly with ECU.

Faulty gear selection switch.

Check switches and wiring.

Park brake sticking.

Check park brake assembly.

Faulty transmission harness.

Check transmission harness for continuity and connector.

ECU damaged by overtightening (early ECU units only)

Check/Change ECU.

Faulty transmission dump input.

Check transmission dump switch and wiring.

Faulty solenoid(s).

Check solenoids and wiring.

Faulty gear selection switch.

Check switch and wiring.

Low oil pressures.

Check clutch pack pressures. Check mainline pressure.

Mechanical problems.

See Section F - Transmission

Faulty speed sensor signal.

Check speed sensor and wiring. Check speed sensor installation (ie. distance from transfer gear)

Incorrect ECU fitted.

Check parts information.

Water ingress/sticking clutch pistons.

See General 069 (F105 N.Am).

Missing gears.

No 4th gear (not applicable to three speed).

9803/3630

Issue 1


Section C



Speed Sensor

19 - 3

19 - 3

Fault Finding Guide - continued FAULT

POSSIBLE CAUSE

REMEDY

Downshift protection not working (if fitted).

Faulty speed signal.

Check speed sensor and wiring.

No transmission dump

Faulty transmission dump input.

Check transmission dump switch and wiring.

No two/four-wheel drive switching (where fitted).

Faulty four-wheel drive switch.

Check four-wheel drive switch and wiring.

Faulty four-wheel drive solenoid.

Check solenoid and wiring.

Faulty ECU (Not 5 speed)

Check solenoid and wiring

Faulty four-wheel drive input.

Check four-wheel drive switch and wiring.

Four-wheel braking operating.

Check footbrake switch and wiring.

Bad earths at battery isolator or engine.

Check ECU plug sealing, check earths at battery isolator.

Transmission dump wire chafing

Check wiring

ECU getting hot.

Four-wheel drive solenoid coil short circuit (Not 5 speed).

Check four-wheel drive solenoid coil.

Transmission will not downshift.

Speed too fast for selected downshift.

Slow machine with brakes.

Machine will not perform a reversal.

Machine travelling too fast to select a reversal in direction (Not 5 speed).

Slow machine with brakes.

Test unit or PC diagnostic tool will not communicate.

Faulty connecting lead.

Check lead and connection.

No power to ECU.

Check power is being supplied to ECU Pins 17 & 18 (18 Pin ECU) Pins 23 & 24 (36 Pin ECU)

Blown fuse on ECU replacement

ECU fitted wrong way round (18 Pin ECU only)

Fit ECU correct way round and replace fuse.

Spurious gear changes

Water in ECU connections

Check connector seals fitted/replace ECU.

Bad earth at battery isolator or engine.

Check/tighten as required

Reverse selection problems

Rear light harness/alarm wires faulty.

Check wiring. Unplug harness and re-try

No automatic upshifts (5 Speed Only)

Will not upshift if foot is off the accelerator.

Check accelerator switch adjustment.

Faulty accelerator switch

Check accelerator switch and wiring.

Intermittent four-wheel drive.

Intermittent drive

9803/3630

Issue 1


Section C



Speedometer

20 - 1

20 - 1

Calibration Procedure * Note: The procedure detailed below shows how to change the calibration figure from 204260 to 193950. This is given as an example only and is not the correct figure to be used. 1

With the calibration button A depressed, switch the ignition switch to ‘IG’. Keep the button depressed until the digital display B on the speedometer display reads "PULSE".

B 2

3

After approximately three seconds the display changes to show the current calibration figure with the digit before the last one flashing (the last digit cannot be altered).

A

378780

A378780

Enter the correct calibration figure. Each digit is entered in turn by pressing button A the required number of times; in this example the digit must be changed to ‘5’. Press button A five times. After a pause, the display automatically changes to show the next digit flashing.

The next digit required is ‘9’. Press button A nine times. The next digit flashes.

Continue in this way until all the digits have been entered.

378790

4

Once the complete calibration figure has been entered, the display changes to total or partial distance display.

Calibration is now complete.

* Note: The calibration figure for use with Loadall machines fitted with currently approved tyres is 312130.

9803/3630

Issue 4*


Section C

www.WorkshopManuals.co.uk Electrics Schematics

24 - 1


24 - 1

Wire/harness numbers - explanation of: Each wire has its own unique identification number, this number is printed on the wire every 50 mm (2 inches) approx. The wire numbers are listed on the following pages and identify the source and final destination of all the wires used on the machine. Also printed on the wire is the part number of the harness the wire originates from; the harness part number is shortened, so for instance, if the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted). The illustration shows a typical connector and wires. To summarise, the number stamped on the wire in the example shown identifies the following: 819 9/371

= The wires unique identification number. = The part number of the harness that the wire originates from.

S171860

Finally, some more points to notice regarding wire identification: 1

Wires will continue to have the same number even after passing through a bulk head connector into a different harness.

2

Wires in splices are identified by using the original input wire number and then a suffix letter. So for instance wire 000 is an original input wire, this wire starts at the starter switch and its destination is one side of fuse B1. Splices from this original wire are identified 000A (from fuse B1 to fuse A9), 000B (from fuse A9 to fuse B8) and so on.

3

The wire number categories are as follows: 000 to 199 LIVE FEEDS - Wires in this number bracket are allocated to live feeds when the starter switch is at IGN position, heater start circuits and start circuits. 200 to 399 BATTERY FEEDS - Wires in this number bracket are allocated to battery feeds. 400 to 599 INSTRUMENTS - Wire in this number bracket are allocated to instruments, (alternator to tacho, fuel gauge senders to fuel gauges etc. 600 to 799 EARTH PATHS - Wires in this number bracket are allocated to earth paths. 800 to 999 SWITCHED SUPPLIES - Wires in this number bracket are allocated to switched supplies to lights, horn etc. from switches and relays.

9803/3630

Issue 1




www.maskinisten.net



www.maskinisten.net


Section C

Electrics


Schematics

25 - 1

25 - 1

48

601

601

600

601

600

600

601

601

601

601

601

601

600

600

600

600

601

600

601

600

601

600

600

601

601

601

601

*

411

601

841

800

59

801

8

57

44

28

105

42

16

49

M

854

120

917

9

34 102

25

003

120

22

851

884

829

F3

F4

115

F2

101

004

120

F1

M

104

600

(SLC)

21

4

38

M

31

106

51 15

3

100

1 2 3

925

911

926

55

109

901

1

56

33

26

64

52

17 23

824

M 41

39

826

M

2

6

66

61

820

7

601

65 848

5

50

885

883

37

601

600

M

601

27

825

60

45

43 24

601

47

601

32

18

601

14

840

12

601

856

400

856

58

F5

F7

F6

F8

F9

F11 F12

000

000

200

200

F13

001

+++ 914

414

19 30 413

11 20

54

46 36

35

40

53

601

62

1

2

3

4

5

6

7

886

8 819

853

29

1 2

13 10

823

907

W

X

Y

Z

3 4

822

5

821

6

Z X Y 63

A313910

9803/3630

Issue 5*


Section C


25 - 2


25 - 2

530 Machines - without Neutral Start Relay (Serial No. 767001 to 768836) To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. Key 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 59

Battery Battery isolator Starter motor Ignition switch Starting aid Auto relay High Speed Control relay Pump dump switch Single lever control Sway isolation relay Sway/Auxiliary change-over Auxiliary change-over valve 1 Sway isolation switch Auxiliary A solenoid Auxiliary A/B switch Auxiliary B relay Auxiliary A relay Auxiliary B solenoid Auxiliary change-over switch Auxiliary change-over relay Auxiliary change-over valve 2 Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Transmission dump switch Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Heater/air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary Switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heater seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay ESOS Two wheel steer solenoid Four-wheel/crab steer solenoid

60 61 62

63

64 65 66

Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel

Steer Sensor Wiring: Terminal 1 2 3

Wire Code 820 or 819 600 or 601 810 or 109

9803/3630

Wire Colour Black Blue Brown

Description Signal Earth Feed

Issue 4*


Section C

www.WorkshopManuals.co.uk Electrics *Schematics

25 - 3


25 - 3

530 Machines - without Neutral Start Relay (Serial No. 767001 to 768836) To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. Key 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 99 100 101 102 103 104 105 106 107 108 109 110 111

Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Water temperature sender Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay Powershift control unit Park brake Four wheel brake relay Foot brake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand sidelights Trailer rear Left hand sidelights Trailer rear Left hand worklights Front worklight switch Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Trailer rear Steering column switch Screen wash pump Right hand indicators Trailer rear Left hand indicators Trailer rear

Note: Powershift control unit (78) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections.

9803/3630

Issue 4*


Section C

Electrics

25 - 4

Schematics


Section www.maskinisten.net C 25 - 4

601

600

*

304

84

G 80

871

75

85 9 15 16 1 13 10 7 2 5 4 3 17 18 12 6

74

89

83

79

873

86

87 88

94 92

109

101

99 96

100

106

98

90

108

104

82

78 123

108

119

95 118

73

840

105

91

200

808

97

898

70

833

77

831

68

841

76

72

450

69

832

827

71

601

600

601

600

81

103

93

102

111

107

304

110 304 806 805 838 301 840 841 110

836

F30

838

F28

F23

F29

F19

F17

F15

F22

F26

F21 874

F25

F14

F24

F16

F18

832

A313920

9803/3630

Issue 5*



Section C

Electrics


Schematics

26 - 1

26 - 1

49

601

601

601

600

600

600

601

601

601

601

601

601

600

600

600

600

601

600

601

600

600

601

600

600

601

601

601

*

411

28

601

800

60

801

925

58

45

53

16

29

56 854

911

901

1 2 3

120

917

50

M

926

10 106

M

600

32

22

26 120

23

35 102

(SLC)

003

15

104

52 39

5

105

43

18

100

1

57

34

27

901

24

65

109

9

824

M 42

40

826

M

2

7

67

62

820

8

601

66 848

841

601

51

883

6

601

601

600

M

38

825

61

46

44 25

601

48

601

14

840

33

19

59 601

856

400

856

17

F12

F11

874

F13

F9

F8

301

F6

F5

115

F4

F3

101

F2

120

F7

810

F1

004

851

884

3 M

200

200

+++ 842

414

20 853

31 413

12 21

55

47 37

36

41

54

601

63

1

2

3

4

5

6

7

886

8 819

30 4

1 2

13 11

823

907

W

X

Y

Z

3 4

822

5

821

6

Z X Y 64 A313890

9803/3630

Issue 5*


Section C


26 - 2


26 - 2

530 Machines - With Neutral Start Relay and ECU Controlled Transmission (Serial No. 768837 to 770053) To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. Key 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

Battery Battery isolator Starter motor Neutral start Ignition switch Starting aid Auto relay High Speed Control relay Pump dump switch Single lever control Sway isolation relay Sway/Aux change-over Sway isolation switch Auxiliary change-over valve 1 Auxiliary A/B switch Auxiliary A relay Auxiliary A solenoid Auxiliary B relay Auxiliary B solenoid Auxiliary change-over switch Auxiliary change-over relay Auxiliary change-over valve 2 Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Transmission dump switch Safe Load Indicator (SLI) SLI Transducer Heater/air conditioning fan Air conditioning unit Air conditioning switch Face level fan Air conditioning compressor Air conditioning relay Binary switch Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay

58 59 60 61 62 63

64

65 66 67

Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel


Wire Code 820 or 819 600 or 601 810 or 109

9803/3630



Issue 4*


Section C


26 - 3


26 - 3

530 Machines - With Neutral Start Relay and ECU Controlled Transmission (Serial No. 768837 to 770053) To check if a neutral start relay is fitted, try starting the engine with the transmission in gear. Key 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 99 100 101 102 103 104 105 106 107 108 109 110 111 112

Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Water temperature sender Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay Powershift control unit Parkbrake Two wheel drive switch Four wheel drive brake switch Foot brake Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklights Sidelight relay Main light switch Primary fuse Right hand Sidelights Trailer rear Left hand sidelights Trailer rear Front worklight switch Left hand worklights Right hand worklights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear foglight switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear Left hand indicators Trailer rear

Note: Powershift control unit (79) only shows input connections from the mainframe harness. Refer to the ECU fault finding information in this section for control unit output connections.

9803/3630

Issue 3*


Section C

Electrics

26 - 4

Schematics



*

601

600

803

304

82

871

76

86 9 15 16 1 13 10 7 2 5 4 3 17 18 12 6

75

90

84

80

873

87

88 89

106

92 95

200

808

840

99

93

100 97

110

102 101

109

107

98

91

300

85

G

898

71

833

78

831

69

841

77

73

450

70

832

827

72

601

600

601

600

83

105

81

79 123

108

72

119

118

96

104

94

103

112

108

304

803

124 100

111

401 806 805 838 301 840 841 110 829

836

F30 F28

F26

F25

F24

F23

F29

F19

F17

F15

874

F22

F21

F14

F16

F18

832

810

A313900

9803/3630

Issue 4*



Section C

Electrics


Schematics

47

601

400

601

27

601

601

58

41 48

M

820

854

11

100

926

54 1 2 3

901

15

105

901

4

109

55

31

26

63

51

200

23

56

43

824

40

925

8 004

M

38

826

M

17 (PP)

7

65

848

883 800

12

64

60

801

5

601

601

49

841

003

36

18

003

16

600

M

32

825

59

44

42 24

601

46

601

13

57 601

840

6

601

601

601

600

600

601

601

601

601

601

601

600

600

600

600

601

601

600

601

600

601

600

601

27 - 1

411

601

601

601

27 - 1

30 22

25

33 102

20

106

M

600

14 9

104

50 37

840

2

884

841

851

110 829

F12

F9

F8

F7

F6

F5

115

F3

101

F4

F2

120

120

F1

1

F11

810 810

3

000

000

200

200

F13

842

874

001

M

414

21

19

53

45 35

34

39

52

601

61

1

2

3

4

5

6

7

886

8 819

917

10

29 413

301

853

28 +++

1 2 823

W

X

Y

Z

3 4

822

5

821

6

Z X Y 62 A313870

9803/3630

Issue 5*


Section C


27 - 2


27 - 2

530 Machines - with Relay Controlled Transmission, ECU Not Fitted (Serial No. 770054 to 770958) Key 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 59

Battery Battery isolator Starter motor Neutral start relay Ignition switch Starting aid not used High Speed Control relay Pump dump switch not used Sway/Auxiliary change-over Auxiliary A relay Auxiliary A solenoid Auxiliary A/B switch Auxiliary B relay Auxiliary B solenoid Auxiliary change-over relay 2 Auxiliary change-over valve 1 Auxiliary change-over relay Auxiliary change-over valve 2 Auxiliary change-over switch Boom extend switch Extend relay Extend solenoid Boom retract switch Retract relay Retract solenoid Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch (air con) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid

60 61

62

63 64 65

Crab steer solenoid Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel


Wire Code 820 or 819 600 or 601 810 or 109

9803/3630



Issue 4*


Section C


27 - 3


27 - 3

530 Machines - with Relay Controlled Transmission, ECU Not Fitted (Serial No. 770054 to 770958) Key 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 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125

Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Pump dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Reverse low solenoid Forward HI/LOW relay Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/four wheel drive solenoid Transmission oil temperature switch Parkbrake switch Footbrake switch Four wheel drive brake relay Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Main light switch Primary fuse Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Rear fog light Steering column switch Front wash/wipe motor Right hand indicators Trailer rear

126 Left hand indicators 127 Trailer rear

9803/3630

Issue 4*



Electrics

Section C

Section www.maskinisten.net C

*Schematics

27 - 4

27 - 4

601

600

601

600

600

601

601 600

601

809

601

601

803

601

856 807

96

89

827

97

117

108

113

116

120

600 601

200 601

600

104

119

109

118

601

124

815

126

103

600

111 106

127

108 98

119

872

93

890

83

115 112

92 90

79

75

812

852

861

78

G

87

91

857

71

82

110

105

99

88

871

874

121

94

859

600

86

600

84

100

114 107

601

81

808

601

80

76

69

811

808

72

863

67 68

125

85

73 70

450

601

600

600

300

304

401

118

807

124

806 805 838 301 840 841

F30 F29

F26

F25

123

122

839

F24

F23

F22

827

F19

F21

F18 F17

F15

815

F16

102

3 SPEED ONLY

77

809

101

601

107

95

F28

110

107

74

A313880

9803/3630

Issue 4*



Section C

Electrics


Schematics

601

601

200 901 926

22

105

51

52

601

820

1 2 3 854

19

45

901

14

38 M

933

12

53

100

21 882

17

61

48

28

934

6

54

40

931

826

37

925

004

932

824

M

109

M 35

935

63

56

883

4

62

58 848

841

601

46

853

24

601

601

600

M

33

825

57

601

800

801

43

41

39

601

840 851

18

13

55 601

601

601

600

600

600

601

601

601

601

601

601

601

29

20

15 7

411

5

28 - 1

44

23

400

11

600

600

600

600

600

600

600

601

601

601

28 - 1

47

850

120

30

102

810

2

9

106

34 M

27

301 840

884 114

451

841

16

110 829

829

810

F12

F11

F9

F8

F7

F6

F5

115

F4

F3

3

F13

842

F2

F1

F10

10

1

101

810

874 000

874

200

200

001

M

+++ 414

+++

8

25 413

50

42 32

31

36

601

301

26

49

59

1

2

3

4

5

6

7

819

886

8

1 2 823

W

X

Y

Z

3 4

822

5

821

6

Z X Y 60 A314050

9803/3630

Issue 5*


Section C


28 - 2

Section C www.maskinisten.net 28 - 2

530, 540 Sway Machines (from Serial No. 770959) Key 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

Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used HSC pump dump switch Auxiliary change-over valve 2 Sway/Auxiliary change-over switch Auxiliary change-over valve 1 Auxiliary A switch Auxiliary A solenoid Auxiliary B switch Auxiliary B solenoid Joystick isolation switch Single lever control - extend Extend solenoid Single lever control - retract Retract solenoid Auxiliary 2 A switch Auxiliary 2 B switch Auxiliary change-over valve 2 Auxiliary change-over relay Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid

59

60

61 62 63

Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel


Wire Code 820 or 819 600 or 601 810 or 109

9803/3630



Issue 3*


Section C


28 - 3


530, 540 Sway Machines (from Serial No. 770959) Key 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 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124

Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Forward HI/LOW relay Reverse low solenoid Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake Four wheel drive brake relay Footbrake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Primary fuse 3 Main light switch Primary fuse 2 Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear


9803/3630

Issue 4*


601

600

601

600

600

601

827

79

118 859

85

82

98

92 94

109

103

97

86

300

600

600

601

601

601 601

600

120 116

114

600

808

600

863

78 74

67

601

65

113 106 450

70

600

600

601

807

95

87

811

68

83 808

66

601

807

71

601

601

601

601

809 601


601 600

Schematics

601

28 - 4


601

Electrics

601

Section C

872

73

890

200

601

816

104

110

118

600

107 96

601

90

126

600 601

119

101

858

117 601

815

105

108

123

81

115

125

77

112

124

88

G

102

91

200

76

857

861

111

119

852

69

84

89 600

80 874

812

871

304 124 108

118

100 401 806 805 838 301 840 841

F30

F28 F29

F26

F25

F24

F23

122

121

839

F22

F21 F19

F17

F15

815

F18

601

100

F16

F35

F34

F33

F31

99 807

3 SPEED ONLY

75

F32

93

107

809

110 829

832

107

F14

72

A314060

9803/3630

Issue 4*



Section C

Electrics


Schematics

601

601

16

848 105

45

926

51

52

820

824

100

M 1 2 3 854

21

47

(DR)

102

120

2

106

34 M

26

810

53

38

901

11

61

48 200

901 882

18 933

9

54

40

931

826

925

37

27

934

004

932

14

601

600 601

841

M

35

109

M

6

63

56

883

4

62

58

853

19

601

601

46 601

801

33

931

932

43

M

15

825

57

41

39 800

10

7

840

851

12

55 601

28

601

5

400

601

601

600

600

600

601

601

601

601

601

601

600

23

17

29 - 1

44 411

20

601

601

600

600

600

600

600

601

601

601

29 - 1

30

301 840

884 451

841

13

22

110 829

829

810

F12

F11

F9

F8

F7

F6

F5

115

F4

F3

101

F13

842

F2

F1

1

F10

114

810

874

874 000

3

200

200

001

M

+++ 414

+++

8

24 413

50

42 32

31

36

601

301

25

1

49

2

3

4

5

6

7

8

59 819

886

1 2 823

3 4

W

X

Y

Z X Y

Z 822

5

821

6

60

A314070

9803/3630

Issue 3*


Section C


29 - 2


29 - 2

530, 540 Non-Sway Machines (from Serial No. 770959) Key 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

Battery Battery isolator Starter motor Ignition switch Starting aid Neutral start relay not used Pump dump switch Auxiliary A switch Auxiliary A solenoid Auxiliary B switch Auxiliary B solenoid Joystick isolation switch Boom extend switch Extend solenoid Boom retract switch Retract solenoid Auxiliary 2 A switch Auxiliary change-over relay Auxiliary change-over valve 2 Auxiliary 2 B switch Stabilizer isolation switch Auxiliary change-over valve 1 Safe Load Indicator (SLI) SLI transducer Heater/air conditioning fan Air conditioning switch Heater/air conditioning unit N/A Face level fan Air conditioning compressor Air conditioning relay Binary switch (air conditioning) Rear wiper switch Rear wiper motor Roof wiper switch Roof wash pump Roof wiper Front wiper Radio/cassette Heated seat Digital clock Warning buzzer Trailer indicators Hazard switch Indicator relay Hazard diode Interior light Rotating beacon switch Rotating beacon Primary fuse Primary fuse Ignition relay Engine Shut-Off Solenoid Two wheel steer solenoid Four-wheel/crab steer solenoid Four wheel steer solenoid Crab steer solenoid

59

60

61 62 63

Steer Mode Control Unit W Four-wheel/crab steer relay X Two wheel steer relay Y Crab steer relay Z Four wheel steer relay Steer mode switch X Two wheel steer select Y Crab steer select Z Four wheel steer select Front sensor Rear sensor Instrument panel


Wire Code 820 or 819 600 or 601 810 or 109

9803/3630



Issue 2*


Section C


29 - 3

Schematics


530, 540 Non-Sway Machines (from Serial No. 770959) Key 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 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124

Air filter blocked switch Engine oil pressure switch Transmission oil temp switch Steering column switch Alternator Fuel sender Water temperature switch Steering column switch Horn Reverse relay 2 Ignition relay 2 Transmission dump switch Transmission dump relay Reverse 1 relay Forward relay Drive relay Parkbrake relay Reverse HI/LOW relay Reverse high solenoid Forward HI/LOW relay Reverse low solenoid Forward high solenoid Forward low solenoid Driveshaft relay Layshaft solenoid Mainshaft solenoid Two/Four wheel drive solenoid Transmission oil temperature switch Parkbrake Four wheel drive brake relay Footbrake Two wheel drive switch Brakelights Brakelights Trailer rear Reverse alarm Auxiliary power socket Rear worklight switch Rear worklight Sidelight relay Primary fuse 3 Main light switch Primary fuse 2 Right hand sidelight Trailer rear Left hand sidelight Trailer rear Front work light switch Left hand work lights Right hand work lights Right hand dip beam Left hand dip beam Right hand main beam Left hand main beam Rear fog light switch Trailer rear Steering column switch Front wash/wipe motor Right hand indicators Trailer rear


9803/3630

Issue 3*


601

600

600 601

600

601

827

79

118 859

85

82

98

92 94

109

103

97

86

300

600

600

601

601

601 601

600

120 116

114

600

808

600

863

78 74

67

601

65

113 106 450

70

600

600

601

807

95

87

811

68

83 808

66

601

807

71

601

601

601

601

809 601


601 600

Schematics

601

29 - 4


601

Electrics

601

Section C

872

73

890

200

601

816

104

110

118

600

107 96

601

90

126

600 601

119

101

858

117 601

815

105

108

123

81

115

125

77

112

124

88

G

102

91

200

76

857

861

111

119

852

69

89 600

84

80 874

812

871

304 124 108

118

100 401 806 805 838 301 840 841

F30

F28 F29

F26

F25

F24

F23

122

121

839

F22

F21 F19

F17

F15

815

F18

601

100

F16

F35

F34

F33

F31

99 807

3 SPEED ONLY

75

F32

93

107

809

110 829

832

107

F14

72

A314060

9803/3630

Issue 3*




www.maskinisten.net



www.maskinisten.net

Section C



Schematics

30 - 1

30 - 1

530, 540 Machines with Manual Auxiliary Controls (from machine Serial No. 775402) 535 Machines (from machine Serial No. 777362) Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamps switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Transducer - Load Moment Indicator (LMI) Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge Alternator

* Optional fan reversing circuit shown at inset X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn Note: All the items listed here are not necessarily fitted to all machines in the range.

9803/3630

Issue 3*



Section C

Electrics


Schematics

30 - 2

30 - 2

*

16

2

6

31 17A

11A 12A

12B

13A

18

19A 20

23 21

32

26 27 28 29 30

10

3 8

22

9

X

11

12

13 15

17

601JR

1 19

601JM

7

601JN

4

33 132

24

1840a

25 14

1840

133

5

5A

171

131

417050

160-02292-1

9803/3630

Issue 3*


Section C

Electrics

30 - 3

Schematics



54

*

35

36

38

39

41

43

44

57

45 46

47

48

49

53

60

62 65 61

55 58

40 37 34

42

56 50 51

52

59

63

64

34A

160-02292-2

9803/3630

Issue 1


Section C


30 - 4 *


30 - 4

530, 540 Machines with Manual Auxiliary Controls (from machine Serial No. 775402) 535 Machines (from machine Serial No. 777362) Key 34 34A 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

Sidelight relay Fuse link 2 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Roof/rear washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Trailer indicator warning light Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater

Note: All the items listed here are not necessarily fitted to all machines in the range.

9803/3630

Issue 1


Section C



Schematics

30 - 5

30 - 5

530, 540 Machines with Manual Auxiliary Controls (from machine Serial No. 775402) 535 Machines (from machine Serial No. 777362) Key 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

Column switch - LH Horn Reverse Hi/Lo relay Reverse Lo relay Reverse Hi relay Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay 2nd auxiliary relay 2nd auxiliary solenoid Hitch/boom hydraulics solenoid Hitch switch Sway switch Sway diverter solenoid Sway valve Sway valve 2nd auxiliary push button Isolation switch Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab Steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated (†) not fitted to 3-speed machines.

9803/3630

Issue 1



Section C

Electrics


Schematics

30 - 6

30 - 6

95 69

70

96

67 75

79

76

80

83 84

97

87 88 89 98

71 †

86 90

66

94 Z X Y

92 91 68

72

73

74

77

78

81

82

99

85

100 93

160-02292-3

9803/3630

Issue 1



Section C

Electrics


Schematics

6

18

27 23

20

11A 12A 24

21

*

25

4

7

8

9

X 601JR

3 26

601JM

16

601JN

2

13

31 32 33 34 35

10

31 - 1

36 37

31 - 1

1 15

17

19

132

30

22

133 28

1840

12

1840a

11

29 14 5 131 171

5A

417050

160-02291-1

9803/3630

Issue 2*


Section C


31 - 2


31 - 2

530/540 Machines with Single Lever Controls (SLC) (from machine Serial No. 775402) 535 Machines (from machine Serial No. 777362) Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 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

Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition reed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector Brake switch 2/4WD brake relay Brake lamps 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge


9803/3630

Issue 2*


Section C


31 - 3 *


31 - 3

530/540 Machines with Single Lever Controls (SLC) (from machine Serial No. 775402) 535 Machines (from machine Serial No. 777362) Key 38 38A 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Rear wiper switch Rear/roof washer pump Roof wiper motor Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater


9803/3630

Issue 1


Section C

Electrics

31 - 4

Schematics



*

39

40

42

43

47 45

48

50

51 53

54

41

65

60

49

63

58

46

38

61

57

56

59

62

64

66

68

67

44 52

55

160-02291-2

9803/3630

Issue 1



Section C

Electrics


Schematics

31 - 5

31 - 5

100 70

72

73

78

83

79

87

101 91

82

93

95

102

96

86

103

69 †

99 Z X Y

104

89 71

75

76

77

80

81

84

85

88

90

92

94

97

105 98

160-02291-3

9803/3630

Issue 2*


Section C


31 - 6


31 - 6

530, 540 Machines with Single Lever Controls (SLC) (from machine Serial No. 775402) 535 Machines (from machine Serial No. 777362) Key 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

Column switch - LH Horn Reverse Hi/Lo relay Reverse Lo Solenoid Reverse Hi solenoid Diode pack (see Note below) Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay 2nd auxiliary relay 2nd auxiliary solenoid Hitch/boom hydraulics solenoid Hitch switch Joystick isolation switch/lamp 2nd auxiliary extend switch 2nd auxiliary extend solenoid 2nd auxiliary retract switch 2nd auxiliary retract solenoid Auxiliary A/B switch Auxiliary A solenoid Auxiliary B solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 2WS solenoid 4WS solenoid AWS solenoid Crab steer solenoid Proximity switch - front axle Proximity switch - rear axle

Note: All the items listed here are not necessarily fitted to all machines in the range. Note: Diode indicated (†) not fitted to 3-speed machines.

9803/3630

Issue 1


Section C


32 - 1


32 - 1

530FS Super, 540FS Super, 530 SXL, 540 SXL Key 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 30A 30B 31 32 33 34 35 36 37 38 39 40 41

Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 Wax Thermostat E.S.O.S. Rear work lamp switch Rear work lamp Front work lamps switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Heated seat Radio/cassette Digital clock Tracker Load Moment Indicator (LMI) - Transducer LMI Readout Unit Fuse link 1 Instrument panel Warning buzzer Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Water temperature switch Fuel gauge Water temperature gauge Alternator Air suspension seat


9803/3630

Issue 3*


www.maskinisten.net

-

+

LEAD

2

1

www.WorkshopManuals.co.uk 3 M

4

003

LEAD

Electrics

8

Section C

7

5 6

001

+++

Schematics

9803/3630

601

003

32 - 2

842

004 200

601

810

9

000 11

200 601

100

10

000

200 601

11 12

12

105

601 601

13

123

904

601

14

18

601

119

18

17

816

108

15

601

17

16

831

15

906

16

829 25

601 601

20

601

19

866 816

118

21

600

22

818

601

24

23

19

124

601 601

807

808

25

601

26

1 2 3

7

112

29

28

27

301

601 601

28

600

29

30

450

3

30A

30B

31

200

413 414

101

601 601

805 806 106

804 824 826 825 838

32

600

402 403 404

411

3536

31 32 33 34 35

34

401

600 601

405A

8

106

412 408

600

409

601

39

829

601

37 38

A374060 160/13114-1

33

406 407

40 M

000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838 401

405A

151

601

41 *

X

133

131

417050

601JR

1840

601JN

132

171

1840a

601JM

Section C

32 - 2

Issue 3*



www.maskinisten.net

Section C

Schematics

Electrics

43

42

32 - 3

000 001 100 300 301 304 804 805 806 808 810 824 825 826 827 829 838 401

405A

9803/3630

200

828 601

44

21

830

600

829

600

601 22

601

45

827

601

47

46

600 23

834

600

838

600

905

50

48

49

27

600

601

898

601 832 833 24

836

52

51

600 601

805

304

600

803 841 840

M

600

M

600

M

601

M

600

M

601

58

840

54 55

839

601

53

806

601

841

56

59

925 926

57

6

901 849

110

60

854

829 300

62

803

104

601

64

63

400

9

601

61

805 804

802

601 601

66

115

601

M

69

68

886

885

71

72

70

884 883

67

M

5

65

301

600 601

4

882

73

102

000 001

829

79

1

121

601

76

75

74

301 304

808 810 824 825 826

829

401

405A

801 800

850

600

931

600

909

78

600


600

32 - 3

80

Issue 1

600

Section C

77

907

A374070 160/13114-2

932

Section C


32 - 4


32 - 4

530FS Super, 540FS Super, 530 SXL, 540 SXL Key 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicators RH indicators Front washer pump Front wiper motor Rear wiper motor Roof/rear washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Trailer indicator warning light Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater Sway switch Sway diverter solenoid Sway valve Sway valve Sway isolator relay Sway isolator proximity switch


9803/3630

Issue 1


Section C


32 - 5


32 - 5

530FS Super, 540FS Super, 530 SXL, 540 SXL Key 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115

116

117 118 119 120 121 122

Transmission oil pressure switch 5th gear solenoid Speed sensor Mainshaft solenoid Layshaft solenoid Forward high solenoid Forward low solenoid Reverse high solenoid Reverse low solenoid Speedometer Speedometer illumination Throttle switch Column switch - LH Electronic control unit Diagnostic port Horn Parkbrake switch 2nd auxiliary relay 2nd auxiliary solenoid Hitch switch Hitch/boom hydraulics solenoid Joystick isolation switch Diode pack 2nd auxiliary B push button Extend push button Extend solenoid 2nd auxiliary A push button Retract push button Retract solenoid Auxiliary A push button Auxiliary A solenoid Auxiliary B push button Auxiliary B solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay Steer mode selector switch X Two wheel steer Y Crab Steer Z Four wheel steer 2WS solenoid 4WS solenoid AWS solenoid Crab steer solenoid Proximity switch - front axle Proximity switch - rear axle


9803/3630

Issue 1



Section C

Electrics Schematics

600

600

600

600

600

601

106

120

A

315

116

103

6

94 12

15

18

29

28

27

26

25

24

23

7 8 9 10 11 12 13 15 16 17 18 20

102

104 105

107 108

5

6

Z X Y

819

121 820

931

930 932

4

C

110 112 114 122 D

98 100

115 109

5

2

3

13

4

856

3

451 120

2

1

2

1

114

1

10

2

933

873

3

929 934

B

600 107

823 822 821

45

93

4 5 6 7 8

601

119

113

853

850

851

815

871

F

109 111

0

600

601 600

601

601

118

814

874

97

872

R N

117

101 99

1807

860

811

859

86 87 88 89 90 812

857

858

480

894

893

405

85

84

808

92

81

809

96

32 - 6

601

91

82 83

600

600

600

600

600

600

600

600

600

600J

32 - 6

*


14

000

808 810 824 825 826

474

470

470A

001 473

001 301 304

A374081 160/13114-3

95 824 825 826

829 401 405A

9803/3630

Issue 2*



Section C

Electrics

12B

13A

34

19A

32

33

35

16

20

See Sheet 4

35

21

3

* X

34 9

11

12 13

133 19 26

410

17

410

1 4

132

22

15

1840

8

1840a

7

601JM

12A

18

23

601JN

17A

33 - 1

601JR

6

11A

27 28 29 30 31

10

1828

Schematics

33 - 1

2


24 25 14 See Note 2 540-170 (5508 N.Am) Only

171

5A

131

22A

5

417050

160-02290-1

9803/3630

Issue 2*


Section C


33 - 2


33 - 2

533-105 Machines

Key 1 2 3 4 5 5A 6 7 8 9 10 11 11A 12 12A 12B 13 13A 14 15 16 17 17A 18 19 19A 20 21 22 22A 23 24 25 26 27 28 29 30 31 32 33 34 35

Battery Battery isolator Starter motor Starter solenoid Ignition switch Fuse link 2 Starting aid Neutral start relay Ignition feed relay 1 Ignition feed relay 2 E.S.O.S. Rear work lamp switch Rear work lamp Front work lamp switch Front work lamps Auxiliary power connector 2/4WD brake relay Brake lamps Brake switch 2/4WD switch 2/4WD solenoid Reverse relay Reverse lamp Reverse alarm Park brake relay Park brake switch Heated seat Radio/cassette Digital clock Fuse link 1 Transducer - load moment indicator (LMI) Instrument panel Warning buzzer Alternator Air filter blocked switch Engine oil pressure switch Transmission oil temperature switch Transmission oil pressure switch Water temperature switch Fuel gauge Water temperature gauge LH stabiliser lamp switch RH stabiliser lamp switch

* Optional fan reversing circuit shown at inset X 131 Fan reverse switch 132 Fan reverse solenoid 133 Fan reverse horn


9803/3630

Issue 2*


Section C


33 - 3


33 - 3

533-105 Machines

Key 36 36A 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

Sidelight relay Fuse link 1 RH side lights LH side lights Main light switch RH/LH dip beam RH/LH main beam Rear fog light switch Rear fog lamp (optional) Column switch - RH LH indicator lamps RH indicator lamps Front washer pump Front wiper motor Rear wiper motor Rear/roof washer pump Roof wiper motor Rear wiper switch Roof wiper switch Hazard warning switch Hazard warning relay Interior light/switch Beacon switch Beacon lamp Face level fan Air conditioning relay Air conditioning - compressor motor Air conditioning - freeze switch Air conditioning - receiver drier Air conditioning switch Heater/heater fan switch Heater


9803/3630

Issue 1



Section www.maskinisten.net C

46

43

45

33 - 4

41

Schematics

40

33 - 4

38

Electrics

37

Section C

47

48

49 50

51

55

59 61

66 58

56

36

44

39 42

63

54

57

62

60

64

52 53

65

36A

160-02290-2

9803/3630

Issue 1



Section C

Electrics


Schematics

33 - 5

33 - 5

95 79 68

70

75

71

80

90

76

84

91

96

89

97 98

71A

67

88 A

94 69

72

73

74 77

78

81

82

83 85

86

87

92

B

Z X Y

99

C

100 D

93

160-02290-3

9803/3630

Issue 1


Section C


33 - 6


33 - 6

533-105 Machines

Key 67 68 69 70 71 71A 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93

Column switch - LH Horn Reverse Hi-Lo relay Reverse Lo solenoid Reverse Hi solenoid Diode pack Reverse relay Forward relay Forward Hi/Lo relay Forward Hi solenoid Forward Lo solenoid Drive interlock relay Drive shaft relay Layshaft solenoid Mainshaft solenoid Transmission dump relay Stabiliser isolation switch Stabiliser isolation relay Stabiliser isolation solenoid Stabiliser isolation switch Sway isolation switch Sway isolation relay Sway switch Sway diverter solenoid Sway solenoid Sway solenoid Transmission dump push button Steer mode control unit A Four wheel/crab steer relay B Two wheel steer relay C Crab steer relay D Four wheel steer relay 94 Steer mode selector switch X Two wheel steer Y Crab steer Z Four wheel steer 95 2WS solenoid 96 4WS solenoid 97 AWS solenoid 98 Crab steer solenoid 99 Proximity switch - front axle 100 Proximity switch - rear axle


9803/3630

Issue 1




www.maskinisten.net

Section E

www.WorkshopManuals.co.uk Hydraulics

i

Section E www.maskinisten.net i

Contents

Page No.

Technical Data 530 Agricultural 530 Construction 540 Agricultural 540 Construction 535 Machines 533 Machines

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

Connecting/Disconnecting Hydraulic Hoses

2-1

Hydraulic Contamination

2-2

Fault Finding 3-1 Note: For Smooth Ride System (SRS) fault finding, see Smooth Ride System - Fault Finding, this Section Schematics Introduction to Hydraulic Symbols 530, 540 Agricultural Machines 530 Construction Machines (up to Serial No. 770616) 530 & 540 Construction Machines with Single Lever Control (From Serial No. 770617) 530 Construction Machines with Manual Auxiliary Controls (From Serial No. 775402) 540 Construction Machines with Manual Auxiliary Controls (From Serial No. 775402) 535-95 Machines (From Serial No. 777362) * 533-105 Machines (From Serial No. 786756)

4-1 5-1 5-3 5-5 5-7 5-9 5 - 11 5 - 13

Hydraulic Pump - Testing - Removal & Replacement

6-1 7-1

Triple Pump - Dismantling & Assembly

8-1

Double Pump - Dismantling & Assembly

9-1

Valves - Valve Block - Description - Valve Block - Removal & Replacement - Valve Block - Dismantling & Assembly - Tie Rods - Relief Valves - Location - Main Relief Valve (MRV) Testing - Auxiliary Relief Valve (ARV) Testing * - Testing A.R.V.’s Set Higher than the MRV - Checking Servo Pressure - Pilot Pressure Reducing Valve

10 - 1 10 - 2 11 - 1 11 - 3 12 - 1 12 - 2 12 - 3 12 - 4 13 - 1 14 - 1

9803/3630

Issue 8*


Section E


ii

Section E www.maskinisten.net ii

Contents

Page No.

* Fan Motor

- Removal & Replacement (up to M770663) - Removal & Replacement (M770664 on) - Adjustment - Dismantling & Assembly

15 - 1 15 - 3 15 - 5 16 - 1

Rams Lift Ram - 530, 540 Machines Removal and Replacement Lift Ram and Displacement Ram * - 533, 535 Machines Removal and Replacement Displacement Ram - 530, 540 Machines Removal and Replacement Extension Ram - 530, 540 Machines Removal and Replacement Extension Ram (Outer) * - 533, 535 Machines Removal and Replacement Extension Ram (Inner) *- 533, 535 Machines Removal and Replacement Tilt Ram - 530, 540 Machines Removal and Replacement * - 533, 535 Machines Removal and Replacement Sway Ram (if fitted) Removal and Replacement Stabiliser Ram - 533 Machines Typical Rams Fitting New Rod Seal Bleeding Boom - Extension Circuit * (533, 535 Machines) Dismantling and Assembly Extension Ram Make Up Valve Smooth Ride System Technical Data Description Electrical Circuit Diagram Hydraulic System Diagram Fault Finding Accumulators Parallel Lift Boom Raise Cycle Boom Lower Cycle Fault Finding

30 - 1

30 - 3

31 - 1

33 - 1

33 - 3

34 - 1

35 - 1 35 - 3 37 - 1 38 - 1 39 - 1 40 - 1 40 - 3 40 - 5 41 - 1 41 - 2 41 - 3 41 - 3 41 - 4 41 - 5

51 - 1 51 - 2 51 - 3

9803/3630

Issue 8*


Section E


1-1

Technical Data

www.maskinisten.net Section E

1-1

530 Agricultural Machines Triple Pump Main pump Fan pump (Machines to S/N 771429) Fan pump (Machines from S/N 771430) Steer pump 2PR019

82.0 litres/min (18.0 UK gal/min) 35.0 litres/min (7.7 UK gal/min) 36.5 litres/min (8.0 UK gal/min) 43.3 litres/min (9.5 UK gal/min) Priority valve 2VP-EAF-JIJ2V1-00-00-56

Control Valves Type

Parallel service, double acting spools.

Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4

Boom Raise & Lower Carriage Tilt Boom Extend & Retract (electro/servo operated) Auxiliary (electro/servo operated)

Servo Pressure Range Machines to S/N 771429; Machines from S/N 771430;

bar 10 - 20 10 - 30

kgf/cm2 10.2 - 20.4 10.2 - 30.6

lbf/in2 145 - 290 145 - 435

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port)

bar 241

kgf/cm2 245

lbf/in2 3500

138 (220†) 138 138 275

140 (223†) 140 140 280

2000 (3190†) 2000 2000 3987

Boom Lift Boom Extension Tilt Displacement Hitch Sway

Bore mm in 130 5.1 70 2.7 110 4.3 120 4.7 50 1.9 110 4.3

Rod Dia. mm in 70 2.7 50 1.9 50 1.9 60 2.3 25 0.9 50 1.9

Filter Filter Type Filtration Size Relief Valve Setting Suction Strainer

Partial flow ('spin on') 10 microns (0.0004 in) 1.05 bar (15 lbf/in2) 125 microns (0.005 in)

Hydraulic Tank Capacity

112 litres (24.6 UK gals)

Rams

Stroke Open centre mm in mm in 753 29.6 1894 74.5 2470 97.2 5225 205.7 474 18.6 1306 51.4 294 11.5 946 37.2 429 16.8 1028 40.4 136 5.4 629 24.8

Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5 493 19.4

Fan Motor

* Oil Flow (to machine 784534) Oil Flow (from machine 784535) Max fan speed at Max engine rev/min

30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 30.0 litres/min (6.6 UK gal/min) at 105 bar (1523 lbf/in2) 2200 rev/min (to machine 784534); 1800 ± 100 rev/min (from machine 784535)††

† Machines with pick-up hitch. Since this ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine. †† Machines from Serial No 784535 are fitted with fan motors with fixed (non-adjustable) relief valves. Consequently the fan speed may vary by up to ± 100 rev/min from the quoted figure.

9803/3630

Issue 5*


Section E



Technical Data

1-2

1-2

530 Construction Machines Triple Pump Main pump Fan pump (Machines to S/N 771429) Fan pump (Machines from S/N 771430) Steer pump 2PR019


Double Pump Main pump Fan pump

100.0 litres/min (22.0 UK (26.4 US) gal/min) 44.8 litres/min (9.9 UK (11.8 US) gal/min) Priority valve 2VP-EAF-JIJ2V1-00-00-56

Control Valves Type

Parallel service, 4 spools.


Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated)


bar 10 - 20 10 - 30

kgf/cm2 10.2 - 20.4 10.2 - 30.6

lbf/in2 145 - 290 145 - 435

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Crowd, head side (A port) — Carriage Tilt Dump, rod side (B port)

bar 241

kgf/cm2 245

lbf/in2 3500

138 (220†) 138 138 275

140 (223†) 140 140 280

2000(3190†) 2000 2000 3987

Boom Lift Boom Extension Tilt Displacement Hitch Sway

Bore mm in 130 5.1 70 2.7 110 4.3 120 4.7 50 1.9 110 4.3

Rod Dia. mm in 70 2.7 50 1.9 50 1.9 60 2.3 25 0.9 50 1.9

Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8 136 5.4





Fan Motor Oil Flow (to machine 784534) Oil Flow (from machine 784535) Max fan speed at Max engine rev/min


Rams

Sway ram option A.R.V. Sway ram option A.R.V.

Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4 629 24.8


*


9803/3630

Issue 5*


Section E

www.WorkshopManuals.co.uk Hydraulics Technical Data

1-3


1-3

540 Agricultural Machines Triple Pump Main pump Fan pump (Machines to S/N 771429) Fan pump (Machines from S/N 771430) Steer pump 2PR019


Control Valves Type

Parallel service, 4 double acting spools.


Boom Raise & Lower Carriage Tilt Boom Extend & Retract (electro/servo operated) Auxiliary (electro/servo operated)


bar 10 - 20 10 - 30

kgf/cm2 10.2 - 20.4 10.2 - 30.6

lbf/in2 145 - 290 145 - 435

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port) — Boom Extend head side (A port) — Boom Extend rod side (B port)

bar 260

kgf/cm2 263

lbf/in2 3770

138(220†) 138 138 275 241 241

140(223†) 140 140 280 245 245

2000(3190†) 2000 2000 3987 3500 3500

Rams Boom Lift Boom Extension Tilt Displacement Hitch

Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9





* Fan Motor Oil Flow (to machine 784534) Oil Flow (from machine 784535) Max fan speed at Max engine rev/min

Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9

Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8

Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4

Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5



9803/3630

Issue 5*


Section E


1-4


1-4

540 Construction Machines Triple Pump Main pump Fan pump (Machines to S/N 771429) Fan pump (Machines from S/N 771430) Steer pump 2PR019




Control Valves Type



Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary/Sway (electro/servo operated)


bar 10 - 20 10 - 30

kgf/cm2 10.2 - 20.4 10.2 - 30.6

lbf/in2 145 - 290 145 - 435

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, head side (A port) — Carriage Tilt Crowd, rod side (B port) — Boom Extend head side (A port) — Boom Extend rod side (B port)

bar 260

kgf/cm2 263

lbf/in2 3770

138(220†) 138 138 275 241 241

140(223†) 140 140 280 245 245

2000(3190†) 2000 2000 3987 3500 3500

Rams Boom Lift Boom Extension Tilt Displacement Hitch

Bore mm in 140 5.5 70 2.7 110 4.3 120 4.7 50 1.9

Rod Dia. mm in 75 2.9 50 1.9 50 1.9 60 2.3 25 0.9

Stroke mm in 753 29.6 2470 97.2 474 18.6 294 11.5 429 16.8

Open centre mm in 1894 74.5 5225 205.7 1306 51.4 946 37.2 1028 40.4

Closed centre mm in 1141 44.9 2755 108.4 832 32.7 652 25.6 599 23.5







*


9803/3630

Issue 5*


Section E


1-5


1-5

535 Machines Triple Pump Main pump Fan pump (Machines to S/N 771429) Fan pump (Machines from S/N 771430) Steer pump 2PR019




Control Valves Type



Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side * — Auxiliary, head side — Carriage Tilt Dump, rod side (A port) — Carriage Tilt Crowd, head side (B port)

bar 240

kgf/cm2 244

lbf/in2 3480

220 220 250 240

224 224 255 244

3190 3190 3626 3480

Note: Since the auxiliary ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine. Rams

Bore mm in 120 4.7 80 3.1 100 4.0 130 4.3 70 2.7 50 2.0

Boom Lift Boom Extension (inner) Boom Extension (outer) Tilt Displacement Hitch Filter Filter Type Filtration Size Relief Valve Setting * Suction Strainer

Rod Dia. mm in 70 2.7 50 2.0 60 2.4 75 1.9 40 1.5 25 1.0

Stroke mm in 1114 43.9 2653 104.5 2653 104.5 336 13.2 750 29.5 530 21.0

Open centre mm in 2571 101.3 5688 224.1 5700 224.6 1110 43.7 1745 68.7 1230 48.4






30.0 litres/min (6.6 UK gal/min) at 190 bar (2760 lbf/in2) 30.0 litres/min (6.6 UK gal/min) at 105 bar (1523 lbf/in2) 2200 rev/min (to machine 784534); 1800 ± 100 rev/min (from machine 784535)†

† Machines from Serial No 784535 are fitted with fan motors with fixed (non-adjustable) relief valves. Consequently the fan speed may vary by up to ± 100 rev/min from the quoted figure.

9803/3630

Issue 5*


Section E



Technical Data

1-6

1-6

533 Machines Double Pump Main pump Fan pump


Control Valves Type

Parallel service, 6 spools with solenoid operated unloader section

Services Operated — Spool 1 — Spool 2 — Spool 3 — Spool 4 Unloader section — Spool 5 — Spool 6

Boom Raise & Lower Boom Extend & Retract Carriage Tilt Auxiliary Right Hand stabiliser Leftt Hand stabiliser

Relief Valve Operating Pressures Main Relief Valve (M.R.V.) Auxiliary Relief Valves (A.R.V.) — Auxiliary, rod side — Auxiliary, head side — Carriage Tilt Dump, rod side (A port) — Carriage Tilt Crowd, head side (B port)

bar 240

kgf/cm2 244

lbf/in2 3480

220 220 250 240

224 224 255 244

3190 3190 3626 3480

Note: Since the auxiliary ARV also controls the pressure to the boom auxiliary service, ensure that this pressure will not cause damage to attachments used with the machine. Rams Boom Lift Boom Extension (inner) Boom Extension (outer) Tilt Displacement Stabilisers

Bore mm in 120 4.7 80 3.1 100 4.0 130 4.3 70 2.7 110 4.3

Rod Dia. mm in 70 2.7 50 2.0 60 2.4 75 1.9 40 1.5 60 2.4



Stroke mm in 1114 43.9 2653 104.5 2653 104.5 336 13.2 750 29.5 392 15.4

Open centre mm in 2571 101.3 5688 224.1 5700 224.6 1110 43.7 1745 68.7 1135 44.7



121 litres (26.6 UK (30 US) gals)

Fan Motor Oil Flow Max fan speed at Max engine rev/min

30.0 litres/min (6.6 UK gal/min) at 105 bar (1523 lbf/in2) 1800 ± 100 rev/min†

† Machines are fitted with fan motors with fixed (non-adjustable) relief valves. Consequently the fan speed may vary by up to ± 100 rev/min from the quoted figure.

9803/3630

Issue 1


Section E

www.WorkshopManuals.co.uk Hydraulics Connecting/Disconnecting Hydraulic Hoses

2-1

The following paragraphs describe how to connect and disconnect hydraulic hoses safely.


2-1

Disconnecting the Hoses

! WARNING

1

Vent the hydraulic pressure as described on this page.

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.

2

Disconnect the hoses. Where the connection is of the quick release type, see section A, contents. For all other hose connections, plug both sides of the connection to prevent loss of fluid.

HYD-1-5

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.

Venting Hydraulic Pressure Stop the engine. When the engine has stopped, vent the hydraulic pressure as follows: a

For the boom and carriage hoses, operate the controls to release the trapped pressure.

b

For the auxiliary, turn the starter key to IGN.

! WARNING

INT-3-1-10/1

3

Check for leaks. See step 2 of Connecting the Hoses.

Select auxiliary 1 or 2 as required, then operate the auxiliary rocker switch. Turn the starter key to OFF and remove the key.

Connecting the Hoses 1

Connect the hoses. Where the connection is of the quick release type, see section A, contents. For all other hose connections, use correct tools and ensure that connections are not cross-threaded. Support the weight of the hose until the connection is made. Do not exceed the recommended torque loading.


2

Check for leaks as follows: a b c

Start the engine. Operate the controls to pressurise the required hose. Switch off the engine. Remove the starter key. Check for signs of leakage at the hose connections.

9803/3630

Issue 1


Section E



Hydraulic Contamination

2-2

2-2

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. 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

9803/3630

Issue 1


Section E

www.WorkshopManuals.co.uk Hydraulics Fault Finding

3-1 Fault 1


3-1

Possible Cause

Lack of power in all hydraulic functions. Low pump flow.

Action Renew pump. Check for external leaks, renew seals. Charge/Priority valve sticking.

2

All mechanically operated hydraulic services slow to operate.

Insufficient hydraulic fluid.

Check for leaks and top up as required.

Hydraulic leaks in system.

Check hoses, renew as required.

Engine performance.

Check engine performance.

M.R.V. setting incorrect.

Check and adjust as required.

Low pump flow

Renew pump. Check pump flow. Check for external leaks, renew seals. Priority valve sticking.

3

All solenoid/servo operated hydraulic services slow to operate.

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

Check pipe lines and renew as required.

M.R.V setting incorrect.


As step 2

As step 2

Low pilot pressure

Check that the pressure maintenance valve is not sticking open. Check the pressure reducing valve(see Pilot Pressure Reducing Valve under Valves). Check servo pressure. See Checking Servo Pressure (this section)

4

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

Solenoid power supply not present.

Check fuse 2 (see Electrics, Technical Data, Fuse Identification, Section C).

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

Check hoses, renew as required.

Associated ram leaking.

Renew seals.

A.R.V. setting incorrect.


Associated valve block section leaking or not operating.

Check for leaks, rectify as required. Check that the control lever is operating the spool, rectify as required.

Associated check valve not opening to allow return of oil to tank.

Check and rectify as required.

Diverter not opening.

Check electrical power supply and valve operation, rectify as required.

9803/3630

Issue 3


Section E

www.WorkshopManuals.co.uk Hydraulics Fault Finding

3-2 Fault 5


3-2

Possible Cause

One solenoid/servo operated hydraulic service fails to operate. (if fitted)

Action

As step 4.

As step 4.

Blockage in solenoid operated valve.

Inspect and clean or renew as necessary. Clean or renew the valve internal filter as necessary.

Solenoid not energised.

Check for faulty solenoid. Renew if necessary. Check relevant electrical circuit, i.e. switches, relays, wiring, etc. and rectify as required.

6

7

*8

9

The engine tends to stall when hydraulics are under load.

Ram creep.

M.R.V setting incorrect.


Engine performance.

Check engine performance.

Associated ram or pipe lines from ram leaking.


Check valve.

Check operation and rectify as required.

Boom extension faults.

See Boom Extension Faults (533, 535 Machines) on the following page.

Boom hoses tangle inside boom (three stage booms only).

Non JCB hoses fitted.

Fit genuine JCB hoses. This is important. Special hose construction used.

Hose twisted during assembly.

Fit hoses carefully to prevent twisting.

Steel pipes under boom bent due to previous hose failures or abuse.

Fit new pipes.

Front lower wear pads worn causing hoses to contact boom.

Fit new wear pads & shim correctly (see Section B, Body and Framework, Boom Shimming - 533, 535).

Hoses not greased on assembly.

Grease hoses.

Hose rollers have insufficient tension.

Adjust to tension correctly (see Rams, Extension Rams (Inner) - 533, 535 Assembling).

Hoses stretched due to three stage boom phasing problems.

Fit new genuine JCB hoses (see first item) and bleed the boom extension circuit. See Boom Extension Faults (533, 535 Machines) and Bleeding - Boom Extension Circuit (533, 535 Machines).

9803/3630

Issue 5*


START

9803/3630


START

Do the inner/intermediate booms go out of phase ?

NO

YES

YES

NO

DONE

YES

Strip outer extension cylinder and ensure make-up valve in piston head is intact and free from contamination. If the valve is damaged, replace with improved type. Adjust make-up valve and bleed cylinders. OK Now ?

NO

Does the inner boom fully retract leaving intermediate boom slightly extended ?

START

DONE

YES

Check MRV in valve block and for leakage past pistons in both rams. Investigate and rectify as required. OK Now ?

NO

YES

NO

START

NO

DONE

YES

Strip inner extension cylinder and ensure make-up valve in piston head is intact and free from contamination. If the valve is damaged, replace with improved type. Adjust make-up valve and bleed cylinders. OK Now ?

NO

Does the outer cylinder fully retract leaving intermediate boom slightly extended ?

DONE

YES

Replace hose-burst check valve(s) on inner/outer extension ram(s) OK Now ?

NO

START

START

Fault Finding

DONE

NO

YES

NO

NO


YES

Fully retract inner and intermediate booms to re-phase hydraulic cylinders. OK Now ?

NO

Does the operator periodically fully retract inner and intermediate booms to re-phase hydraulic cylinders ?

DONE

YES

Renew motor spool in extend slice. See T.I. 5/197 OK Now ?

DONE

YES

Pressure test hydraulic pump (see Hydraulic Pump, Testing). Rectify if required. OK Now ?

DONE

Note 2: For ‘adjust make-up valve’ procedure refer to Extension Ram Makeup Valve.

Note 1: For ‘bleed’ procedure refer to Bleeding - Boom Extension Circuit (533, 535 Machines).

3-3

Are the inner/intermediate booms over-running after de-selecting extend lever or is there an unexpected surge after a retract operation ?

YES

Does the inner/intermediate boom extend or retract ?

NO

Bleed air from hydraulic cylinders OK Now ?

YES

YES

Extension Faults (533, 535 Machines)

Is the machine experiencing boom extend or retract problems ?

* Boom

Section E Section E www.maskinisten.net 3-3

Issue 5*

Section E



Schematics

4-1

4-1

Introduction to Hydraulic 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.

Pumps & Motors

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 ISO1219.

Variable capacity pump two directions of flow

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.

Fixed capacity motor one direction of flow

General (Basic & Functional) Symbols

Spring

Fixed capacity motor two directions of flow

Flow restriction affected by viscosity Variable capacity motor one direction of flow

Direction of flow

Indication of rotation Variable capacity motor two directions of flow Indication of direction and paths of flow Variable control A189660

Rams

Single acting

Double acting A189680

Double ended

Double acting with damping at rod area end A189670

9803/3630

Issue 1


Section E



Schematics

4-2

4-2

Introduction to Hydraulic Symbols (cont’d) Control Valves

High pressure selector (shuttle valve)

Non - return valve

Non - return valve with back pressure spring Throttling orifice normally closed

Pilot operated non - return valve

Throttling orifice normally open

Relief valve

Variable restrictor

A189690

9803/3630

A189700

Issue 1


Section E



Schematics

4-3

4-3

Introduction to Hydraulic 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

Line junction

Pressure sealed tank

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

Quick release couplings - disconnected

A189720 A189710

9803/3630

Issue 1


Section E



Schematics

4-4

4-4

Introduction to Hydraulic 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) A189730

9803/3630

A189740

Issue 1


Section E 4-5

www.WorkshopManuals.co.uk Hydraulics Schematics


4-5

Introduction to Hydraulic Symbols (cont’d) Control Valves Control valves are usually represented by one or more square boxes. Fig. 1 shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (4 boxes - 4 positions etc).

FIG 2

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

Port 3

FIG 3 If the valve spool was moved to Position 1, movement of the spool would connect Port 1 to Port 2, and Port 3 to Port 4. If the valve spool was moved to Position 3, movement of the spool would connect Port 1 to Port 4, and Port 3 to Port 2. It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares.

Port 2

Port 4

Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement. Fig 3 shows a 'D' type spool.

FIG 4

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

9803/3630

Issue 1


Section E


4-6


4-6

Introduction to Hydraulic Symbols (cont’d) Example of Schematic Circuit

Example Circuit Key

Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit, shown below.

A B C D E F G

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.

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

9803/3630

Issue 1


Section E

www.WorkshopManuals.co.uk Hydraulics Schematic

5-1

530, 540 Agricultural Machines Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/Auxiliary options 1B Fan motor 1C Steer valve The pump is mounted on the rear face of the bevel box. The valve block is mounted under the cab on the inboard side. Spools 2F and 2G are pilot operated, controlled by switches and electrical solenoids. The steer pump 1C has an integral priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil returns back to tank. When a machine is fitted with a provision for trailer brakes, trailer brake valve 19 connects at B1 and B2. Return to tank connects into the steer circuit at B3. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 N1 N2 S T 1 1A 1B 1C 1D 1E 1F 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A


Pressure cap breather (if fitted) Filter Filter by-pass See Note 1 Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 2 Main pump Fan pump Steer pump Priority valve Test points Test point (if fitted) Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Tilt spool Extension spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.)- see Note 3 Auxiliary relief valve (A.R.V.)- see Note 3 Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve

3B 3C 4 4A 5 8 8A 9 10 10A 11 11A * 11B * 11C 12 13 13A 13B 13C 13D 13E 14 14A 14B 14C 15 15A 15B 15D 15E 16 17 17A 17B 17C 17D 17E 18 19 19A 19B 19C 19D 20

5-1

Shock valves (option) Main relief valve Cooling fan motor Cooling fan motor drain line (if fitted) Cooler (if fitted) Lift ram Lift ram check valve Displacement ram Tilt ram Tilt ram check valve Extension ram Extension ram check valve Auxiliary relief valve (A.R.V.) (540 only) Auxiliary relief valve (A.R.V.) (540 only) Auxiliary 1 boom quick release couplings Auxiliary 1 with trailer hitch option Diverter valve (chassis) - see Note 4 Trailer hitch ram Auxiliary 1 boom quick release couplings Trailer/Auxiliary quick release coupling Restrictor adaptor - See Note 5. Auxiliary 1 and 2 option Diverter valve (boom) - see Note 4 Auxiliary 2 boom quick release couplings Auxiliary 1 boom quick release couplings Auxiliary 1 and 2 with carriage pin locking option Diverter valve (boom) - see Note 4 Auxiliary 2 boom quick release couplings Manual change over valve Hydraulic pin locking ram Rear power track rod Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve - See Note 6. Front power track rod Trailer brake valve assembly option Pilot valve Brake valve Trailer brake coupling Brake circuit connection Restricted non return valve

Note 1: Later machines have direct return to tank from the Filter F. Note 2: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 3: Early machines have auxiliary relief valves which incorporate check valves. Note 4: Ports B and C of items 13A, 14A and 15A were Ports A and D on machines prior to serial number 775468. Note 5: Restrictor adaptor 13E fitted to improve hitch control on machines fitted with a pickup hitch option. See Technical Information Bulletin 5/195 (E191). Note 6: Steering anti-cavitation valve 17E is by-passed via connector Y, as shown on inset Z, on machines from S/N 773054.

9803/3630

Issue 5*



Hydraulics

Section E

Section Ewww.maskinisten.net

Schematics

5-2

5-2

*

17

15

Z 17A

17C

15D

18 17B

15E

17E

16

15B

17D

15C 15A

Y

17E

14

B3

14B 3 14C 14A 5 3

13

19C

13E

3B

13D

13C 4

2

13B

T

13A

4A 3A

19D 12

A 2G B2

3C

19A

19B

B

2M 2K

B1

B

2M

11B 11C

1F A

1

2E 1E

2H

2M

B 2J

1B A

F 1C

11

A 2F

19

1D

11A

2L

2D

1A

B

2M

F1

10 9

20

10A

2C

B N2

S T F2

2B

2A

2N N1

8A

8 A293711

9803/3630

Issue 4*



Section E

Hydraulics

5-3


5-3

Schematics

*

14 P1

14B

B A C

A

D

P2

14C

B

17

14A T

17A

17C

B 16

18

A

P 17D

17B

13

17E P1

V

C

13C

B A C

A 13G

P2

D

B

2K

2L

13A

13D 13B

5 R

L 3

3B 4

T

3A A 3C P

2G

LS 2

T

12

B

2M

2L

2K A 2E

2J

2H

B

10 9

11

2M

LS

EF

P

1E

11A

A

1

2F

10A

B

1E 2M 1B

1D F

A 1C

2D

1A N1

F1 S

2M 20

2C

N2

B

B

2N 2B T

2A P

8A 8 A259692

9803/3630

Issue 3*


Section E



Schematics

5-4

5-4

* 530

Construction Machines (up to Serial No. M770616) Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/Auxiliary options 1B Fan motor 1C Steer valve The pump is mounted on the rear face of the bevel box.

The valve block is mounted under the cab on the inboard side. Spool 2G is pilot operated, controlled by switches and electrical solenoids. The steer pump 1C has an integral priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil returns back to tank. The schematic shows a number of options, check your machine to see which options apply. On machines with sway option the valve block spool is a motor spool instead of the open centre type spool. Component Key B F F1 N1 N2 S T *1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J * 2K * 2L 2M 2N 3 3A 3B

Pressure cap breather Filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction line Tank Pump assembly - see Note 1. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Tilt spool Extension spool Auxiliary spool (open centre, see 13G) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V) Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve Shock valves (option)

3C 4 5 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 13D 13G 14 14A 14B 14C 16 17 17A 17B 17C 17D 17E 18 20

Main relief valve Cooling fan motor Cooler Lift ram Lift ram check valve Displacement ram Tilt ram Tilt ram check valve Extension ram Extension ram check valve Auxiliary 1 boom quick release couplings Auxiliary 1 with sway option Sway ram Sway ram check valve Auxiliary 1 boom quick release couplings Diverter valve (chassis) Sway/auxiliary spool (motor spool, see 2G) Auxiliary 1 and 2 option Diverter valve (boom) Auxiliary 2 boom quick release couplings Auxiliary 1 boom quick release couplings Rear power track rod Steer mode valve 2 Wheel steer solenoid 4 Wheel and crab steer solenoid 4 Wheel steer solenoid Crab steer solenoid Steering anti-cavitation valve Front power track rod Restricted non return valve

* Note 1: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed.

9803/3630

Issue 3*


Section E


5-5

530 & 540 Construction Machines with Single Lever Control (from Serial No. 770617) Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/Auxiliary options 1B Fan motor 1C Steer valve The pump is mounted on the rear face of the bevel box. The valve block is mounted under the cab on the inboard side. Spool 2G is pilot operated, controlled by switches and electrical solenoids. The steer pump 1C has an integral priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil returns back to tank. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 3 3A 3B 3C


Pressure cap breather Filter Filter by-pass See Note 1. Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly - see Note 2. Main pump Fan pump Steer pump Priority valve Test points Valve block Main relief valve (M.R.V.) Pressure reducing valve (20 bar) Pressure maintaining valve (10 bar) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) Auxiliary relief valve (A.R.V.) (Sway ram option A.R.V.) Load hold check valves (L.H.C.V's) Accumulator Steering unit Steer valve Shock valves (option) Main relief valve

5-5

4 Cooling fan motor 5 Cooler (if fitted) 8 Lift ram 8A Lift ram check valve 9 Displacement ram 10 Tilt ram 10A Tilt ram check valve 11 Extension ram 11A Extension ram check valve * 11B Auxiliary relief valve (A.R.V.) (540 only) * 11C Auxiliary relief valve (A.R.V.) (540 only) 12 Auxiliary 1 boom quick release couplings 13 Auxiliary 1 with sway option (if fitted) 13A Sway ram (if fitted) 13B Sway ram check valve (if fitted) 13C Auxiliary 1 boom quick release couplings 13D Diverter valve (chassis) 13E Diverter valve 13G Sway/auxiliary spool 14 Auxiliary 1 and 2 option 14A Diverter valve (boom) - See Note 3. 14B Auxiliary 2 boom quick release couplings 14C Auxiliary 1 boom quick release couplings 15 Auxiliary 1 and 2 with hydraulic pin lock option 15A Diverter valve - See Note 3. 15B Auxiliary 1 boom quick release couplings 15C Auxiliary 2 boom quick release couplings 15D Hydraulic pin lock ram 15E Manual change over valve 16 Auxiliary 1 with trailer hitch option 16A Diverter valve (chassis) - See Note 3. 16B Trailer hitch ram 16C Auxiliary 1 boom quick release couplings 16D Trailer/Auxiliary quick release coupling 16E Restrictor adaptor - See Note 4. 17 Steer mode valve 17A 2 Wheel steer solenoid 17B 4 Wheel and crab steer solenoid 17C 4 Wheel steer solenoid 17D Crab steer solenoid 17E Steering anti-cavitation valve - See Note 5. 18 Front power track rod 19 Trailer brake valve assembly option 19A Pilot valve 19B Brake valve 19C Trailer brake coupling 19D Brake circuit connection 20 Restricted non return valve 21 Rear power track rod Note 1: Later machines have direct return to tank from the filter F. Note 2: From machine S/N 771430 the positions of fan pump 1B and steer pump 1C of pump assembly 1 are reversed. Note 3: Ports B and C of items 14A, 15A and 16A were Ports A and D on machines prior to serial number 775468. Note 4: Restrictor adaptor 16E fitted to improve hitch control on machines fitted with a pickup hitch option. See Technical Information Bulletin 5/195 (E191). Note 5: Steering anti-cavitation valve 17E is by-passed, as shown on inset Z, on machines from S/N 773054.

9803/3630

Issue 5*



Hydraulics

Section E


Schematics

5-6

5-6

*

16

16E

16D

16C 16B

16A

Z 17

15 17E

17A

17C

18

15E

15B

21

15D 15C

17B

Y

17D

15A 17E 14

3

14C

14B

14A 13 13G

5

3 3B

2M

19C

2K

2L

4

13A 2

13B

3A

13E

13D 13C 2G

19D 3C

2M B2

19A

2K

2L

2H

2J

12

11A

11

19B 2F

B1 2M

19 1

2E 1E 2M

11B 11C 10

1B

1D

9

F

2D 1C

1A

F1

N1

2M 20 2C

N2

B

2B T S

10A

2A

2N 8A

F2

8 A293721

9803/3630

Issue 4*



Section E

Hydraulics

5-7


5-7

Schematics

16 16A

15 16C

17

18 16D

16B

15B 15A

4A 15C B

A

T

P

14D 14F

a

Y

L

3

X

a

b

3

L

R

14E

b

14

14B

14C

13B

13C

R

3B

3C

14A

A

13 B

2 3A

3A

3B

3D

3D

A

13A

2G

3C

P

P

T

4

LS

LS

B

12

2M

T

2K

11A

11

2L A

2F

c

B

c 2M

d

d

2H

2J A

LS

P

1

EF

2E

B

1E 2M 1C 1D

10

P

A

16 19 32

F

1B

F1

1A

9

2D B

2280 rev/min

2M

19 B

10A

2A

8 8A

S

N1

T

20

N2

20D

8A

8

20B

20A 4

160-02300-2

20C

* 9803/3630

16002300-3

Issue 5*


Section E



Schematic

5-8

5-8

530 Construction Machines with Manual Auxiliary Controls (From Serial No. 775402) Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. * The three stage pump assembly shown at X, fitted to earlier machines, comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil returns back to tank. On later machines, a two stage pump shown at Y is fitted. 1A Steer/valve block/auxiliary options 1B Fan motor The main services pump 1A has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil flows from the EF port to the control valve to provide loading/auxiliary services. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M

Pressure cap breather (if fitted) Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump (3 stage pump only) Priority valve Test points Valve block Main relief valve (MRV) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Auxiliary relief valve (A.R.V.) Load hold check valves (LHCVs)

3 3A 3B 3C *4 4A 5 5A 5B 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 14 14A 14B 14C 14D 14E 14F 15 15A 15B 15C 16 16A 16B 16C 16D 17 18 19

Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M784534) Relief valve - 108 bar (from M784535) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve Displacement ram Tilt ram Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings (standard build) Second auxiliary option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Second auxiliary with hydraulic pin locking option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder Sway control valve option One way restrictors Pilot operated check-valve Sway hydraulic cylinder Steer mode valve - See Note 2. Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Wheel steer solenoid Crab steer solenoid Front power track-rod Rear power track-rod Restricted non return valve

Note 1: Pump flow goes direct to the fan motor on nonsway machines. Note 2: Electrically operated steer mode valve shown. Manual version also available.

9803/3630

Issue 4*


Section E



Schematics

5-9

5-9

540 Construction Machines with Manual Auxiliary Controls (From Serial No. 775402) Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The three stage pump assembly shown at X, fitted to earlier machines, comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil returns back to tank. On later machines, a two stage pump shown at Y is fitted. 1A Steer/valve block/auxiliary options 1B Fan motor The main services pump 1A has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil flows from the EF port to the control valve to provide loading/auxiliary services. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 N1 N2 S T 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 2P

Pressure cap breather Return line filter Filter by-pass Neutral circuit feed line Neutral circuit return line Pump suction strainer Tank Pump assembly Main pump Fan pump Steer pump (3 stage pump only) Priority valve Test points Valve block Main relief valve (MRV) Lift spool Extension spool Tilt spool Auxiliary spool Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Auxiliary relief valve (ARV) Load hold check valves (LHCVs)

3 3A 3B 3C *4 4A 5 5A 5B 8 8A 9 10 10A 11 11A 12 13 13A 13B 13C 14 14A 14B 14C 14D 14E 14F 15 16 16A 16B 16C 16D 17 18 19

Steering unit Steer valve Shock valves (option) Main relief valve Cooling fan motor (non-reversible) Relief valve - 190 bar (to M784534) Relief valve - 108 bar (from M784535) Reversible cooling fan motor option Relief valves Fan change-over solenoid Lift ram Counter-balance valve Displacement ram Tilt ram Counter-balance valve Extension ram Counter-balance valve Auxiliary 1 boom quick release couplings Second auxiliary option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Second auxiliary with hydraulic pin locking option Diverter valve (boom) Auxiliary 1 boom quick release couplings Auxiliary 2 boom quick release couplings Manual change-over valve Flow restrictor Hydraulic pin locking cylinder Sway option Steer mode valve - See Note 1. Two Wheel steer solenoid Four Wheel and crab steer solenoid Four Wheel steer solenoid Crab steer solenoid Front power track-rod Rear power track-rod Restricted non return valve

Note 1: Electrically operated steer mode valve shown. Manual version also available.

9803/3630

Issue 4*



Hydraulics

Section E


Schematics

5 - 10

5 - 10

16 16A

15

16C

18

17

15B

16D

16B

15A

4A 15C B

A

T

P

14D 14F 14E

3

14

L

14B

14C

R

3C 14A

A

3A

13

2

B

13C

13B

4

LS

3B T

A

2G

3D

12

2M

P

13A

B

2K

11A

11

2L A

2F B

1E LS

P

2M

1

EF

2H

2J A

2E

1D

1B

1A 16

B

2M

10

36

A

2280 RPM

9

2D

F

B

F1

2M

19 B

10A

2A

8 8A

S

N1

T

20

20D

N2 8A

8

20B

20A 4

20C

160-02300-4

16002301-3

9803/3630

Issue 5*



Section E

Hydraulics

5 - 11


5 - 11

Schematics

16C

16A

T

T

B

17

18

A

P

16B

F P

16D

15C

SA

16

15B

SB

5 15A

Y

L

3

a

b

L

R

Y 3

A

T

P

15D

5B

14D 14E

5A

a

B

A

14

b

15

R

P1

DB

B

P2

14B

14C

13B

13C

C

3B

3B

14F

A

14A

A

13 B

3A

P2

4

3C

3D

P

P

C

A

2G

LS

3C

A DB

4A

3A LS

T

P1

13A

B

12

2P

T

11

11A

A

2F

c

c

B

2P

d

d

A LS

P

EF

2E

B

2P

1C P

F

1B

F1

1A

2D

2280 rev/min

10

9

A B

2P 10A

19 N2

B T

P

S

N1

8

8A 8A

20 20D

20A

8

20B 160-02301-3

20C A343503

9803/3630

Issue 4*


Section E


5 - 12


5 - 12

535-95 Machines (from Serial No. 777362) Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. * The three stage pump assembly shown at X, fitted to earlier machines, comprises three sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor 1C Steer valve The steer pump 1C has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil returns back to tank. On later machines, a two stage pump shown at Y is fitted. 1A Steer/valve block/auxiliary options 1B Fan motor The main services pump 1A has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve, oil flows from the EF port to the control valve to provide loading/auxiliary services. The schematic shows a number of options, check your machine to see which options apply. Component Key B F F1 F2 S T N1 N2 1 1A 1B 1C 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C

Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main services pump Fan pump Steer pump Priority valve Test point Valve block Main relief valve (MRV) Lift spool Extend spool Tilt spool Auxiliary spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Load hold check valves (LHCVs) Steer unit assembly Steering valve Main relief valve Shock valves (option)

3D Non return valve 4 Cooling fan motor (non-reversible) 4A Relief valve - 190 bar (to M784534) Relief valve - 108 bar (from M784535) 5 Reversible cooling fan motor option 5A Relief valves (108 bar) 5B Fan change-over solenoid 12 Auxiliary 1 boom quick release couplings (standard build) 13 Sway control valve (option) 13A Sway ram 13B Pilot operated check valve 13C One-way restrictor 13D One-way restrictor 13E Relief valve 13F Diverter valve 13G Sway valve spool 15A Hydraulic pin lock ram 15B Restrictor 15C Manual changeover valve 15D Auxiliary 2 boom quick release couplings 16 Rear power track rod 17 Steer mode valve (option) 17A 2 wheel steer solenoid 17B 4 wheel and grab steer solenoid 17C 4 wheel steer solenoid 17D Crab steer solenoid 18 Front power track rod 19 Trailer brake valve assembly (option) 19A Pilot valve 19B Brake valve 19C Trailer brake coupling 19D Brake circuit connection 20 Pick-up hitch (option) 20A Solenoid diverter valve (chassis mounted) 20B Pick-up hitch ram 20C Auxiliary 1 boom quick release couplings 20D Trailer/Auxiliary quick release coupling 20E Restrictor adaptor - see Note 2 21 High flow auxiliary (option) 22 Inner extension ram 23 Extension ram check/counter balance valve 24 Outer extension ram 24A Bleed point 25 Regenerative valve 26 Tilt ram 27 Tilt check/counterbalance valve 28 Displacement ram 29 Displacement lift valve 30 Lift ram 31 Lift check/counterbalance valve Note 1: The schematic shows sway and trailer brake options. Pump flow goes direct to fan motor if sway is not fitted. Note 2: Restrictor adaptor 20E is fitted to improve hitch control on machines fitted with pick-up hitch option. See Technical Information Bulletin 5/195 (E191).

9803/3630

Issue 3*


Section E



Schematics

5 - 13

5 - 13

533-105 Machines (from Serial No. 786756) Description The diagram shows all the machine circuits to clarify the way in which they relate to each other. The pump assembly comprises two sections each of which supplies oil to parts of the circuit as follows: 1A Valve block/auxiliary options 1B Fan motor The pump has a priority valve 1D which always gives priority demand to the steer valve 3A. When there is no demand from the steer valve oil flows from the EF port to the control valve to provide loading services. Component Key B F F1 F2 S T N1 N2 1 1A 1B 1D 1E 2 2A 2D 2E 2F 2G 2H 2J 2K 2L 2M 3 3A 3B 3C 3D 4 4A 5 5A 5B 10 10A 10B 11 11A 11B 12

Pressure cap breather Return line filter Filter by-pass Direct return to tank Pump suction strainer Tank Neutral circuit feed line Neutral circuit return line Pump assembly Main pump Fan pump Priority valve Test point Valve block Main relief valve (MRV) Lift spool Extend spool Tilt spool Auxiliary spool Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Auxiliary Relief Valve (ARV) Load hold check valves (LHCVs) Steer unit assembly Steering valve Main relief valve Shock valves Non return valve Cooling fan motor (non-reversible) Relief valve (108 bar) Reversible cooling fan motor option Relief valves (108 bar) Fan reversing valve Left stabiliser ram Left stabiliser lock out valve Pressure switch (optional) Right stabiliser ram Right stabiliser lock out valve Pressure switch (optional) Auxiliary 1 boom quick release couplings (standard build)

15A 15B 15C 15D 16 17 17A 17B 17C 17D 18 21 22 23 24 24A 25 26 27 28 29 30 31

Hydraulic pin lock ram Restrictor Manual changeover valve Auxiliary 2 boom quick release couplings Rear power track rod Steer mode valve (option) 2 wheel steer solenoid 4 wheel and grab steer solenoid 4 wheel steer solenoid Crab steer solenoid Front power track rod High flow auxiliary (option) Inner extension ram Extension ram check/counter balance valve Outer extension ram Bleed point Regenerative valve Tilt ram Tilt check/counterbalance valve Displacement ram Displacement lift valve Lift ram Lift check/counterbalance valve

9803/3630

Issue 1



Section E

Hydraulics

5 - 14


5 - 14

Schematics

17

13

17A

T

17C

T

B

18 P

F

16

A

13G 13F

P

17B

17D

19C

13C

13B

13D

15C

SA

19D

4A

19

B

A

T

P

SB

13E

Y

13A

150 BAR

19B

15B 15A P1

R

15D

P2 B

3

L

N

R

20

19A P

12

P1 c

3C

2

B P2

20C

A

20B

D

C

20E

d

3A

20D

20A

4 A

2G

LS

3D

2K

2L

21

B

3B

P

2M

T

A

2F

2H

25

B

2J

24

2M

LS

P

1

EF

1A 1B

F

16

19

B

Retract

2M

1C

P

Extend

22

24A

2E 1E

1D

A

23

A

32

2D

2280 rev/min

F1

B

28

27

2M

26

Crowd

B N2

2A

N1

Dump

T

P

29

T

S

Dump

F2 Lift

30 31 160/12719 A343502

9803/3630

Issue 2*


Section E


Hydraulics

5 - 15


5 - 15

Schematics

17

13

17A

T

17C

T

B

18 P

F

16

A

13G 13F

P

17B

17D

13C

19C

SA

13B

19D

5

19

B

A

T

P

SB

13E

Y

13A

150 BAR

13D

19B

15C

5B

15B 15A

5A

P1

R

15D

P2 B

3

L

R

N

3C

20

19A

4

P

12

P1 c

2 3A

B P2

20B

C

20E

20A A

LS

2G

3D

P

20D

D

d

4A

3B

20C

A

T

2K

2L

B

21

2M A

2F

2H

25

B

2J

24

2M 1E LS

P

1

EF

23

22

A 24A

2E

B

2M 1D

1A

P

1B

F

16

A

36

2D

2280 rev/min

F1

B

28

27

2M

26

B 2A

T S F2

P

T

29

N1 N2

30 31

A343503

160/12719

9803/3630

Issue 1*



Section E

Hydraulics


Schematics

5 - 18

17

T

18

5 - 18

B

P

A

10A

2

10 A

5

2Q

10B

B

2M B

A

T

P

5B 2P

5A

3

L

11B 15C

4 12

2N

3A

2G

LS

3D

2K

B

2J

A

2F

1

EF

2L

21 2H

P

15A

15D

2M

1E

P

LS

15B

A

4A 3B

11

B

2M

R

3C

T

11A

A

B

25

2M

24

1A 16

22

A

1C 1B

23

2E

36

B

2280 RPM

2M A

B

2D

F

B

28

2M

27

26

F1 S

T F2

2A N1

P

29 T

30 N2

160-13379

31

9803/3630

Issue 1




www.maskinisten.net

Section E



*Hydraulic Pump

6-1

6-1

Triple Pump (Machines to S/N 771429)

Testing Triple Pump The three sections of the pump assembly individually supply hydraulic oil to the main services circuits, to the steering circuit and to the hydraulic cooling fan circuit.

A

B

D

C

Note: Hose C goes direct to tank D. Double Pump The two sections of the pump assembly individually supply hydraulic oil to the main services circuits or the steering circuit, as determined by the priority valve, and to the hydraulic cooling fan circuit. Test equipment

A335540

The test equipment required comprises flow meter 1, pressure gauge 2 and load valve 3, interconnected as shown.

Main Services Pump 1

Triple Pump (Machines from S/N 771430)

Switch OFF the engine and operate the controls to vent residual pressure.

B

D

A

! WARNING Make the machine safe before getting beneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake is engaged and the transmission is in neutral. Disconnect the battery. Chock both sides of all four wheels.

C

5-3-2-1/1

2

Disconnect hose A at point B and connect the test equipment between the two, the output end of flow meter 1 to hose A and load valve 3 to point B.

! CAUTION

A335550

Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8

Double Pump

A

B

1

2

3 416111 A326060

9803/3630

Issue 5*


Section E

www.WorkshopManuals.co.uk Hydraulics Hydraulic Pump

6-2


6-2

Main Services Pump (cont’d) ! 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

3

Reconnect the battery.

4

Start the engine and operate a hydraulic service until the oil reaches normal operating temperature. Set the steering and the main valve block controls to neutral.

5

Set the engine speed to 2200 rev/min. Adjust load valve 3 to set up the operating pressure, see Technical Data for correct pressure (M.R.V. pressure). The flow rate should be as follows: 82 litres (18 UK gal, 21.6 US gal)/min.

! WARNING Take care when disconnecting the hydraulic hoses and fittings as the oil will be HOT. Trans 1-2

6

On completion, switch OFF the engine and allow to cool before disconnecting the test equipment and reconnecting the hydraulic pipework.

7

If the flow rate is low or it is not possible to obtain the operating pressure required, see Fault Finding in this section.

9803/3630

Issue 1


Section E



Hydraulic Pump

6-3

6-3

Steering Pump Note: The steering pump is part of the triple pump only. In the case of machines fitted with the double pump, the steering circuit is supplied from the main services pump, as determined by the priority valve. 1

1


3


2

A326060

* Machines to S/N 771429 *

5-3-2-1/1

2

D

Disconnect hose C from the EF port of steering priority valve W. Connect the test equipment, the output end of flow meter 1 to hose C and load valve 3, via a suitable hose, to the EF port of the steering priority valve.

C

! 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

3


4

Set the steering and the main valve block controls to neutral. Start the engine and run until it reaches the normal operating temperature.

5

Set the engine speed to 2200 rev/min. Adjust load valve 3 to achieve an operating pressure of 185 bar (2680 lbf/in2). The flow rate should be 41 litres (9 UK gal, 10.6 US gal)/min.

! WARNING Take care when disconnecting the hydraulic hoses and fittings as the oil will be HOT.

W

A335540

* Machines from S/N 771430 *

D

C

Trans 1-2

6


7


9803/3630

W A335550

Issue 1


Section E

www.WorkshopManuals.co.uk Hydraulics Hydraulic Pump

6-4

6-4


Fan Pump 1



D


F

5-3-2-1/1

2

Disconnect hose F from the pump output port. Connect the test equipment, the output end of flow meter 1 to hose F and load valve 3, via a suitable hose, to the pump output port.

! CAUTION

A335540

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


3


4

Set the steering and the main valve block controls to neutral. Start the engine and run until it reaches the normal operating temperature.

5

Set the engine speed to 2200 rev/min. Adjust load valve 3 to set up the operating pressure: To M784534

D

190 bar (2760 lbf/in2)

From M784535 108 bar (1566 lbf/in2) The flow rate should be 30 litres (6.6 UK gal, 7.9 US gal)/min.

F

! WARNING

A335550

Take care when disconnecting the hydraulic hoses and fittings as the oil will be HOT. Trans 1-2

6


7


1

Double Pump

2

3 F A326060

9803/3630

416111

Issue 1


Section E

www.WorkshopManuals.co.uk Hydraulics *Hydraulic

7-1 * Removal

and Replacement


Pump

7-1


Carry out General Safety procedures, see Machine Safety, Section 3. Before removing and dismantling the pump, check flow and pressure. If either of these are low and cannot be corrected at the relief valve, the appropriate pump section must be renewed completely. 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 or dismantling the pump, make sure the exterior of the pump and working area is thoroughly cleaned and free of possible sources of contamination. Removal

B A

! WARNING

Make the machine safe before getting beneath it. Park the machine on level ground. Make sure the engine is stopped, the parking brake is engaged and the transmission is in neutral. Disconnect the battery. Chock both sides of all four wheels.

E

S263930

D

C


5-3-2-1/1

1


2

Drain hydraulic tank.

3

Disconnect and plug feed hoses, making a note of the adapters from which they have been removed. Cap the adapters.

4

Remove screws A. Disconnect and plug suction pipe B. Blank off the pump port.

5

Triple pump only Remove socket head screws C. Disconnect and plug outlet pipe D. Blank off the pump port.

6

The pump is heavy and will require support before removing it. Undo bolts E, remove pump from machine.

7

Retain the drive coupling.

A

B

E

D

C

A313800

Double Pump

B

A E

416111

9803/3630

Issue 3*


Section E

www.WorkshopManuals.co.uk Hydraulics *Hydraulic Pump

7-2 * Removal


7-2

and Replacement (continued)

Replacement Replacement is a reversal of the removal procedure. Use new ‘O’ ring seals. Fit drive coupling, engage pump drive into coupling, support pump until bolts E have been torque tightened (see below). Bolts E should be 10.9 grade M12 tuff lok, make sure the correct bolts are fitted. Refit suction pipe B and outlet pipe D or outlet hose F. Torque tighten retaining screws A and C (see below). After fitting a new or serviced pump and before starting the engine screw the MRV out 4 full turns. Adjust the MRV, see Valves, Main Relief Valve in this Section. Check fan motor speed and adjust as required, see Fan Motor, Adjustment in this Section. Torque Settings Item A/C E

Nm 46 96

Kgf.m 4.7 9.7

lbf.ft 34 70

9803/3630

Issue 4*


Section E 8-1



8-1

*Triple Pump Pump Configuration Early Machines

P

3

2

1

Later Machines

P 3

2

1 A313820

See Note opposite

9803/3630

Issue 6*


Section E

www.WorkshopManuals.co.uk Hydraulics *Triple Pump

8-2


8-2

Dismantling and Assembly Note: The exploded view opposite shows the triple pump fitted to early machines (to S/N 771429). The configuration of its sections is shown opposite and detailed below. On later machines (from S/N 771430) the configuration has changed to that also shown opposite and detailed below. The main difference between early and later machines is the revised location of the steering pump and the steering priority valve P (item 4 on early machines). Items 4 and 6 shown opposite only apply to early machines. The steering priority valve on later machines, being mounted on the side of the centre pump section, does not feature in the dismantling/assembly procedures.

6

Remove splined coupling 13 and O-rings 14. Discard the O-rings.

7

Use a soft faced hammer to separate end cover 5 from pump body 7.

8

Remove drive gear 15 from its bore. Pushing it out of the rear body will also remove balance plate 16 complete with seal 17 and seal energiser 18. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.

9

Remove driven gear 19, followed by balance plate 20 complete with seal 21 and seal energiser 22. Discard the seal and seal energiser.

10

Discard O-ring 23.

11

Use a soft faced hammer to separate end cover 8 from pump body 11.

12 Before removing and dismantling the pump, check flow and pressure. If either of these are low the pump must be renewed. 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.

Remove drive gear 24 from its bore. Pushing it out of the pump body will also remove balance plate 25 complete with seal 26 and seal energiser 27. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.

13

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.


14

Discard O-ring 32.

Mark all sections to ensure correct assembly and keep pump components with their relative pump section.

15

Use a soft hammer to separate mounting flange 33 from pump body 12.

Unless specified otherwise the following dismantling/ assembly procedures apply to all machines.

16

Remove circlip 1 and shaft seal 34.

17

Remove driveshaft 35 from pump body 12. Removal will also remove balance plate 36 complete with seal 37 and seal energiser 38. Discard the seal and seal energiser.

18

Remove driven gear 39 followed by balance plate 40, seal 41 and seal energiser 42. Discard the seal and seal energiser.

19

Discard O-ring 43.

20

Remove all sealant from the contact faces of the mounting flange/pump body and end cover/pump body interfaces.

21

Wash all components and immediately apply a coating of hydraulic oil to prevent corrosion.

Function Section Early Machines 1

Later Machines

Main Services

2

Cooling Fan

Steering

3

Steering

Cooling Fan

Dismantling 1

Remove the four bolts 2 and serrated washers 3 which clamp the units together.

*2

Machines to S/N 771429 Use a soft faced hammer to separate priority valve housing 4 from end cover 5. Remove and discard the O-rings 6.

3

Use a soft faced hammer to separate pump body 7 from end cover 8.

4


5

Use a soft faced hammer to separate pump body 11 from pump body 12.

9803/3630

Issue 3*


Section E 8-3


9803/3630


8-3

Issue 4*


Section E


8-4


8-4

Dismantling and Assembly (cont’d) 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 35 where shaft seal 34 runs.

d

The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

e

The driveshaft splines are worn or severely fretted.

f

The gear "cut-in" area in the low pressure side of the pump body is deeper than 0.15 mm (0.006 in) or has a torn or pitted appearance.

9803/3630

Issue 4*


Section E 8-5

www.WorkshopManuals.co.uk Hydraulics Triple Pump

9803/3630


8-5

Issue 1


Section E


8-6

Triple Pump

8-6


Dismantling and Assembly (cont’d) Assembly When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. 1

15

Apply a small amount of JCB Threadlocker and Sealer to the exposed face of pump body 11 (i.e. the face containing the clamping bolt holes).

Fit shaft seal 34 into mounting flange 33 with its garter spring facing into the pump. Fit circlip 1 into its groove in the flange. Coat the seal lips with high melting point grease.

16

Fit end cover 8 in its original position, as marked earlier.

17

Fit O-rings 10 into the grooves on the face of pump body 7. Install splined coupling 9.

Note: If the seal recess is scored, it is permissible to seal outside diameters with JCB Multigasket to prevent leakage.

18

Fit pump body 7 onto end cover 8 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

19

Fit seal 20 and seal energiser 21 into balance plate 22. Ensuring that the seals do not fall out, carefully feed the balance plate into pump body 7 with the two small holes through the balance plate to the low pressure side (i.e. side with a port blank).

20

Fit drive gear 15 so that it locates with splined coupling 9. Fit driven gear 19.

21

Fit balance plate 16 in its original position (i.e. with the two small holes to the low pressure side). Fit seal 17 and seal energiser 18 into the balance plate.

22

Fit O-ring 23 into end cover 5.

23


24


25

Fit seals 6 into end cover 5.

26

Machines to S/N 771429 Fit priority valve housing 4 in its original position, as marked earlier.

27

Install the four bolts 2, each with a serrated washer 3, and tighten evenly and progressively.

28

Pour a small amount of clean JCB Special Hydraulic Fluid into the ports. Check that driveshaft 35 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.

2

Stand pump body 12 on its rear face. Fit seal 37 and seal energiser 38 into balance plate 36.

3

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of pump body 12 with the two small holes through the balance plate to the low pressure side of the body (i.e. side with the large 4-bolt port pattern).

4

Insert driveshaft 35 and driven gear 39 into the original bores.

5

Fit balance plate 40 over the driveshaft and gear stub. Insert seal 41 and seal energiser 42 into the balance plate.

6

Fit O-ring 43 into the groove on mounting flange 33.

7

Apply a small amount of JCB Threadlocker and Sealer to the face of pump body 12 which seals with mounting flange 33 (i.e. the face containing the clamping bolt holes).

8

9

Carefully feed mounting flange 33 over driveshaft 35 in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot. Support the pump assembly on the mounting flange 33 (but not the driveshaft). Fit O-rings 14 into the grooves on the face of pump body 12. Install splined coupling 13.

10

Fit pump body 11 onto pump body 12 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

11


Torque Settings

12


Item 2

13


Nm 100

Kgf. m 10

Ibf. ft 74

9803/3630

Issue 1


Section E


9-1

Double Pump

9-1


4 10 20

2 1

5

22 7 3 21

9803/3630

Issue 1


Section E


9-2

Double Pump

9-2


Dismantling and Assembly Before removing and dismantling the pump, check flow and pressure. If either of these are low the pump must be renewed. 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. Mark all sections to ensure correct assembly and keep pump components with their relative pump section. Unless specified otherwise the following dismantling/ assembly procedures apply to all machines.

14

Remove driven gear 29 followed by balance plate 30, seal 31 and seal energiser 32. Discard the seal and seal energiser.

15

Discard O-ring 33.

16

Remove all sealant from the contact faces of the mounting flange/pump body and end cover/pump body interfaces.

17

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:

Dismantling 1

Remove the three capscrews 1 which attach the priority valve 2 to the pump body 3.

2

Remove priority valve 2 and discard O-rings 4.

3

Remove the four bolts 5 and washers 6 which clamp pump body 7 to pump body 3.

4

Use a soft faced hammer to separate pump body 3 from pump body 7.

5


6

Use a soft faced hammer to separate pump body 7 from end cover 10.

7

Remove drive gear 11 from its bore. Pushing it out of the rear body will also remove balance plate 12 complete with seal 13 and seal energiser 14. Discard the seal and seal energiser. Note the position of the driveshaft and the balance plate to ensure correct reassembly.

8


9

Discard O-ring 19.

10

Remove capscrews 20 and nuts 21 holding mounting flange 22 to pump body 3.

11

Use a soft hammer to separate mounting flange 22 from pump body 3.

12

Remove circlip 23 and shaft seal 24.

13

Remove driveshaft 25 from pump body 3. Removal will also remove balance plate 26 complete with seal 27 and seal energiser 28. Discard the seal and seal energiser.

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 25 where shaft seal 24 runs.

d

The balance plate faces are scored, particularly in the area adjacent to the gear root diameter.

e

The driveshaft splines are worn or severely fretted.

f

The gear "cut-in" area in the low pressure side of the pump body is deeper than 0.15 mm (0.006 in) or has a torn or pitted appearance.

9803/3630

Issue 1


Section E


9-3

Double Pump

9-3


4 10 20

2 1

5

22 7 3 21

9803/3630

Issue 1


Section E

www.WorkshopManuals.co.uk Hydraulics Double Pump

9-4


9-4

Dismantling and Assembly (cont’d) Assembly When carrying out the following procedure, renew all seals and O-rings. Lubricate using JCB Special Hydraulic Fluid. 1

Fit shaft seal 24 into mounting flange 20 with its garter spring facing into the pump. Fit circlip 23 into its groove in the flange. Coat the seal lips with high melting point grease.

14


15

Fit O-ring 19 into end cover 10.

16


17


18

Install bolts 5, each with a serrated washer 6, and tighten evenly and progressively.

19

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.

Note: If the seal recess is scored, it is permissible to seal outside diameters with JCB Multigasket to prevent leakage. 2

Stand pump body 3 on its rear face. Fit seal 27 and seal energiser 28 into balance plate 26.

3

Ensuring that the seals do not fall out, carefully feed the balance plate into the bores of pump body 3 with the two small holes through the balance plate to the low pressure side of the body (i.e. side with the large 4-bolt port pattern).

4

Insert driveshaft 25 and driven gear 29 into the original bores.

5

Fit balance plate 30 over the driveshaft and gear stub. Insert seal 31 and seal energiser 32 into the balance plate.

6

Fit O-ring 33 into the groove on mounting flange 22.

7

Apply a small amount of JCB Threadlocker and Sealer to the face of pump body 3 which seals with mounting flange 22 (i.e. the face containing the clamping bolt holes).

8

Carefully feed mounting flange 22 over driveshaft 25 in its original position, as marked earlier. Use a soft faced hammer to tap the flange onto its location spigot.

9

Attach mounting flange 22 to pump body 3 with capscrews 20 and nuts 21.

10

Support the pump assembly on the mounting flange 22 (but not the driveshaft). Fit O-rings 9 into the grooves on the face of pump body 3. Install splined coupling 8.

11

Fit pump body 7 onto pump body 3 in its original position, as marked earlier, ensuring that it locates on the dowels and that the clamping bolt holes line up.

12


13


9803/3630

Issue 1




www.maskinisten.net

Section E

www.WorkshopManuals.co.uk Hydraulics *

10 - 1

Valves


10 - 1

Valve Block Description The control valve shown is a typical six spool with unloader section. Machines without stabilisers are fitted with 4 spool valves and no unloader section. Depending on your machine some sections are pilot operated and controlled by an electrical switch, see schematics section for the various types fitted. When the spools are actuated, oil from the pump passes into the service ports A or B, operating the relevant hydraulic ram. See the applicable hydraulic schematic for service port connections. * Four spool control valves do not have the unloader section 2H, spools 2J and 2K fitted, but the procedure remains the same. T

Oil from the pump enters the control valve at P, passing the adjustable main relief valve (M.R.V.) 2A, the pressure reduction valve 2B and pressure maintaining valve 2C. The pressure reduction valve 2B (20 bar) and the pressure maintaining valve 2C (10 bar) are set at the manufacturers and are not adjustable. As the spools 2D, 2E, 2F, 2G, 2J and 2K are in neutral, the oil passes round their central waists, the spool lands preventing the oil from entering the service ports. On reaching the end housing the oil enters the exhaust gallery and is discharged back to tank T. The control valve also incorporates adjustable auxiliary relief valves (A.R.V.'s) 2N, 2P, 2L and 2M. The unloader section 2H isolates the stabilisers when solenoid 2R is energised. Note: Pressure reducing valve 2B and pressure maintaining valve 2C are not fitted to machines with manual auxiliary controls from machine serial number 775402.

A 2K B 2Q A 2J B

T

2Q

2H

2K

B A

2R A

2G

2J

B A

B

2Q 2L

2H

2M A

2F 2N

2P

2Q

B

2G

B

A

A

2E B 2Q

2F

B A

A 2D

2E

B

B

A

2Q

2D

B

A

2C 2B

2A

P A296340

P S296330

9803/3630

Issue 3*


Section E



Valves

10 - 2

10 - 2

* Torque Settings

Removal Position the boom and fit the Safety Strut, see Machine Safety, Section 3.

Item A

Nm 91

kgf.m 9.3

lbf ft 67

Carry out General Safety procedures, see Machine Safety, Section 3. Remove the stabiliser control lever knobs and gaiters from inside the cab (if fitted) . Make sure that all residual hydraulic pressure has been vented. Disconnect the control linkages B at the valve spools. Disconnect the valve block electrical solenoids. Disconnect and plug all hydraulic hoses, label each to ensure correct position on replacement. Support valve block, undo and remove screws A, lift out control valve block. Note: The four spool valve block, although smaller, has the same procedure. Replacement Replace the control valve block by reversing the removal procedure.

A

After replacement check the operation of the mechanical control linkages B. The boom control lever in the cab should be vertical when in neutral. If the lever is not vertical undo locknuts C at each end of the control rod D. Turn the rod D to lengthen or shorten as required. Tighten locknuts C.

A

After replacement, check M.R.V. and A.R.V. pressures.

B

C

D

B B

A A296350 S296330

9803/3630

Issue 3*


Section E


11 - 1


Valves

11 - 1

Valve Block Dismantling

Assembling

The exploded view shows the spool control valve block containing lift spool 2D, extension spool 2E, tilt spool 2F and sway/auxiliary spool 2G.

Ensure that valves 2Q are located on tie rod 2 and that intersection seals are located in their grooves as at X.

The Main Relief Valve (M.R.V.) 2A and the Auxiliary Relief Valves (A.R.V.’s) 2L, 2M, 2N and 2P are screw adjustable, for pressures see Technical Data, this section. M.R.V. 2A and A.R.V.’s 2L, 2M, 2N and 2P may be dismantled only for cleaning and inspection as no parts can be serviced. * Note: When a pressure reducing valve is fitted it cannot be adjusted (see Pilot Pressure Reducing Valve).

Shim 3 is fitted between all sections including end sections but only over tie bar 2. Nuts 1 must be tightened evenly while the valve is lying on a flat surface with the ports facing upwards. This will allow the spool sections to assume their correct positions. Torque Settings - old type tie rods Item 1 1A

Nm 26-28 40.5

Kgf.m 2.6-2.9 4.15

lbf.ft 19-21 30

* Note: See Tie Rods page 11-3 for correct assembly and torque figures for new tie rods. For older type tie rods torque figures are given below.

341650

9803/3630

Issue 4*


Section E



Valves

11 - 2

11 - 2

Valve Block (continued) Dismantling

Assembling

The spools and their components can be removed without separating the valve sections but tie rod 2 must be removed to release load hold check valve plugs 2Q. Do not remove back up ring A as this cannot be renewed in service.

Renew all ‘O’ rings.

It is important to identify the spools with their respective bores to ensure correct replacement as some valve blocks have motor spools. Failure to fit spools correctly could result in machines not operating correctly and damage to components.

Ensure the spools are fitted in their original bores. If filter 8 is not fitted it could result in the solenoid failing to operate. Check the filter is clean and fitted correctly. Torque Settings Item 4 6

Nm 6 9-12

Kgf.m lbf.ft 0.5 4 0.9-1.2 7-9

9803/3630

Issue 1


Section E



Valves

11 - 3

11 - 3

Tie Rods New tie rods with revised torque figures have been introduced. Later valve blocks have flats machined into the end of the inlet and outlet covers as shown at A. The new tie rods are identified by a shorter thread and a dimple B machined into the end of one rod. The ends with the shorter thread must be assembled to the outlet cover end of the valve. The rod with the dimple must be fitted in the position shown with the dimple assembled at the inlet cover end or early failure of the valve block can occur.

B

P

T

A C

The spring washers are replaced by hardened flat washers.

T

C

A347890

The new tie rods can be fitted to older valve blocks. Torque Figures Item B C

Nm 39-41 26-28

Kgf m 4.0 2.8

lbf ft 29-30 19-20

9803/3630

Issue 1




www.maskinisten.net

Section E



Valves

12 - 1

12 - 1

Relief Valves Location The main control valve is fitted with a main relief valve (M.R.V.) and several auxiliary relief valves (A.R.V.). The location of the relief valve is dependant on the machine type. Use the diagrams below, the applicable hydraulic circuit schematic and technical data page to correctly identify the relief valve and its pressure setting. Relief Valves 2 3 4 5 6 7

-

8

-

Main relief valve (M.R.V.) Auxiliary service port B (A.R.V.) Auxiliary service port A (A.R.V.) Tilt ram - rod side (A.R.V.) Tilt ram - head side (A.R.V.) Boom extend ram - head side port A (A.R.V.) (540 only) Boom extend ram - head side port B (A.R.V.) (540 only)

P = Inlet from pump

T = Return to tank

* Note: On 533, 535 machines the tilt ram head side A.R.V. (Port B) is set higher than the rod side A.R.V. (Port A).

*

533, 535 Machines

530, 540 Agricultural

T 3 6 8

4 4

A

B

3

A

B

2

A

B

1

A

5 7

3 7 5

4

B

4

A

B

3

A

B

2

A

B

1

A

2 P

T

T

B

2

530, 540 Construction

8 3 5 67

4

A

B

3

A

B

2

A

B

1

A

2 P

9803/3630

4

B

P

6 8

A296261

Issue 5*


Section E

www.WorkshopManuals.co.uk Hydraulics Valves

12 - 2


12 - 2

Main Relief Valve (M.R.V.) ! 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

Testing

Select boom lower service and hold ram fully closed. Increase engine to max speed while checking maximum gauge reading which should be as specified in Technical Data. If pressure should exceed specified data before max rev/min is reached, return the control lever to the neutral position and reduce engine speed to idle rev/min. Position the boom and fit the Safety Strut, see Machine Safety, Section 3. Switch OFF the engine, vent residual pressure and adjust the M.R.V.

Operate control levers to vent residual pressure. Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge to test point 1.

If necessary, adjust the M.R.V. by releasing locknut A and screwing body B in or out as required. Retighten locknut. Screwing the M.R.V adjuster B inwards increases the pressure. Screwing the adjuster outwards decreases the pressure.

Start engine and run at idle rev/min. Operate the machine to normal operating temperature before testing as follows:

B A

A296360

1

S296300

9803/3630

Issue 2


Section E



Valves

12 - 3

12 - 3

Auxiliary Relief Valve (ARV) * Testing * A.R.V's which are set below the M.R.V. pressure can be tested simply by operating the relevant service. For tilt ram A.R.V's. which are set above the M.R.V. pressure, a different procedure is required (see Testing A.R.V.’s Set Higher Than the M.R.V.). * Note: The engine must not be run at maximum speed as a significant increase in pressure will be recorded. * Operate the machine to normal operating temperature before checking the following.


* To test A.R.V's set below M.R.V. pressure proceed as follows: *1

With the pressure gauge connected to test point A, run engine at idle rev/min and operate the relevant service to full travel. Hold while checking the maximum gauge reading which should equal the relevant A.R.V. operating pressure specified in Technical Data.

*2

If the pressure is not as specified release the switch or return the control lever to neutral as applicable.

*

Position the boom and fit the Safety Strut, see Machine Safety, Section 3. 3

With the engine stopped, turn the starter switch to ON.

4

Operate the switches and control levers to vent residual hydraulic pressure. Identify the relevant A.R.V. - see Relief Valves, Location. Adjust the A.R.V. as detailed for M.R.V.

5

Repeat steps 1 to 4 until the correct pressure reading is obtained.

*6

Remember that A.R.V.’s are fitted for each side of the relevant service. Operate the controls fully in the opposite direction and check the gauge reading. Follow the procedure in steps 2 to 4 as applicable.

* *

*

9803/3630

A

S296300

Issue 2*


Section E


12 - 4 *


12 - 4

Testing A.R.V.’s Set Higher Than the M.R.V.

* 530, 540 Machines Tilt Ram The rod side A.R.V. of the tilt ram is set higher than the M.R.V. Proceed as follows:

! WARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. Trans 1-2

1

Lower the boom fully, switch off the engine and operate all controls to vent residual pressure.

2

Disconnect hose F from connector G.

3

Blank off connector G.

4

Connect the pressure gauge to hose F.

5

Start the engine and slowly raise the boom to approximately 45° angle. As the boom is raised the pressure gauge will show the A.R.V. pressure which should be as shown in Technical Data.

6

If the pressure is not as specified, return the control lever to the neutral position. Position the boom and fit the safety strut, see Machine Safety, Section 3.

7

Switch OFF the engine and vent residual pressure. Identify the A.R.V. - see Relief Valves, Location. Adjust the A.R.V. as detailed for M.R.V.

8


9

After completing the test, fully lower the boom, stop the engine and vent pressures. Disconnect the gauge and reconnect tilt ram feed hose F to connector G.

G F

A331440

9803/3630

Issue 4*


Section E


12 - 5


12 - 5

Testing A.R.V.’s Set Higher Than the M.R.V. (cont’d) * Tilt Ram - 533, 535 Machines The A.R.V. on the head side of the tilt ram is set higher than the M.R.V.

! WARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. Trans 1-2

1

Raise the boom and fit the safety strut. See Machine Safety (Section 3).

2

Switch off the engine and operate all controls to vent residual pressure.

3

Disconnect hose A and fit tee piece B. Connect a 0-400 bar pressure gauge to the tee piece as shown.

4

Start the engine and crowd the forks fully back. Remove the safety strut and slowly lower the boom. The pressure gauge will show the A.R.V. pressure as the boom is lowered. See Technical Data (this section) for recommended pressure setting.

5

If the pressure is not as specified, return the control lever to the neutral position. Position the boom and fit the safety strut.

6

Switch OFF the engine and vent residual pressure. Identify the tilt ram head side A.R.V. (Port B). See Relief Valves, Location. Adjust the A.R.V. as detailed for M.R.V.

7


8

Disconnect the gauge and reconnect tilt ram feed hose.

9803/3630

A B

346500

Issue 5*


Section E 13 - 1 *



Valves

13 - 1

Checking Servo Pressure - electrically operated spools only 1

Stop the engine. Turn the ignition key to ON, but do not re-start the engine.

2

Release residual servo pressure by repeatedly operating the control switch(es) for the solenoid/servo operated services.

3

Separate hose A from filter B and install tee-piece C between the two. Connect a pressure gauge D to the tee-piece.

4

Start the engine and allow the hydraulic system to get up to normal working temperature.

5

Monitor the pressure readings (see Technical Data) as the engine speed is gradually increased to maximum.

Note: It is important that the pressure does not fall below the lower limit at tickover.

A C B

D

A313980

9803/3630

Issue 2*


Section E


14 - 1 * Pilot


Pressure Reducing Valve

*

14 - 1

A

A2

A3

One of three types of pilot pressure reducing valve may be fitted (see item 2B - Valve Block, Dismantling and Assembly). The cartridge in each of them is non-adjustable. The cartridge is not serviceable beyond cleaning. A cartridge should be renewed complete if wear or damage is evident. Faulty performance is most likely to occur if the ball valve is sticking closed. A build-up of foreign material or incorrect setting-up are the most likely causes of sticking.

A5 A2

A1

* Inspection

A3

A4

A5

Check the ball valve is free to move by shaking the cartridge and listening for a mechanical rattling noise. Dismantle the components of the cartridge in the numbered sequence. Clean all parts with clean hydraulic fluid and inspect for signs of wear or damage. On cartridge B only, check that setting screw B1a is set at the correct depth X as shown. If the depth setting is too great this could be the cause of a sticking ball valve. Remove the setting screw and degrease the setting screw thread and the mating tapped hole. Apply two or three drops of JCB Threadlocker and Sealer to the thread of setting screw B1a and insert to the required depth into the tapped hole. After allowing the thread sealant time to set (refer to the product information). Re-assemble the cartridge and torque tighten where necessary. Renew the complete cartridge if damage is evident. Refit the cartridge to the valve block and check for correct operation.

A4

A1

A318970

* A1 A2 A3 A4 A5 *

Plug Spring Pilot reducing spool Roll pin Ball

B B1a

B1

B2

B3

B5

Torque Settings Item A1 B1 B4

Nm 20 - 24 20 - 24 6-8

kgf m 2 - 2.4 2 - 2.4 0.6 - 0.8

lbf ft 14.7 - 17.7 14.7 - 17.7 4.4 - 5.9

B4 X = 4.5 mm * B1 B1a B2 B3 B4 B5

A318980

One-way check adapter Setting screw Spring Spring seat Plug Piston

9803/3630

Issue 3*


Section E



Fan Motor

15 - 1

15 - 1

*

E

F C

E A293760

D B A

S266801

9803/3630

Issue 2*


Section E

www.WorkshopManuals.co.uk Hydraulics Fan Motor

15 - 2 *


15 - 2

Removal and Replacement (Up to M770663)

* Removal 1

Position machine on firm level ground. Fully lower the boom, apply parking brake, stop engine and remove the starter key.

2

Vent all residual hydraulic pressure by operating boom, tilt and extension controls.

3

Disconnect and cap exhaust hose A, pressure hose B and seal drain hose D from fan motor. Label hoses for identification.

4

Prevent fan from turning and release tab washer and undo nut C.

5

Remove drive key (not shown) and fan from motor.

6

Undo bolts E and remove fan motor.

Replacement Mark the fan mounting hub with reflective tape F before assembling. Replacement is the reversal of the removal procedure. Torque Settings Item C E

Nm 54 47

kgf m 5.5 4.8

lbf ft 40 34.5

9803/3630

Issue 3*


Section E



Fan Motor

15 - 3

15 - 3

G

G H

F

A293760

D

C

C

C B

A

C

E A293400

9803/3630

Issue 1


Section E


15 - 4


15 - 4

Removal and Replacement to M784534)

* (M770664 Removal 1


2


3

Disconnect and cap feed and return hoses A and B.

4

Undo fixing screws C and remove fan guard D.

5

Undo the 4 bolts E and lift away the fan and motor assembly.

6

Prevent the fan from turning and release the tab washer and then unto bolt F.

7

Remove the drive key (not shown) and the fan from the motor.

8

Undo motor retaining bolts G and remove the motor.

Replacement Mark the fan mounting hub with reflective tape H before assembling. Replacement is the reversal of the removal procedure. Torque Settings Item F G

Nm 54 47

kgf m 5.5 4.8

lbf ft 40 34.5

9803/3630

Issue 3*


Section E



Fan Motor

15 - 5

15 - 5

H

H 391270

F

391280

D

A

E

B

F

391250

9803/3630

Issue 2*


Section E


15 - 6


15 - 6

Removal and Replacement (From M784535) Removal 1


2


3

Disconnect and cap feed and return hoses A and B.

4

Disconnect and cap case drain hose C (reversible fan option only).

5

Undo fixing screws D and remove fan guard E.

6

Undo the 4 bolts F and lift away the fan and motor assembly.

7

Prevent the fan from turning and release the tab washer and then unto nut G.

8

Remove the drive key (not shown) and the fan from the motor.

9

Undo motor retaining bolts H and remove the motor.

Replacement Replacement is the reversal of the removal procedure. Torque Settings Item G H

Nm 28 42.5

kgf m 2.9 4.3

lbf ft 20.6 31.3

9803/3630

Issue 1


Section E



Fan Motor

15 - 7

15 - 7

Adjustment Machines to M784534 only Note: On machines with later style cooling packs (M784535 onwards), the fan motor relief valve(s) is/are factory set to give a maximum fan speed of 1800 ± 100 rpm. This is NOT adjustable.

! WARNING DO NOT adjust the fan motor while the engine is running. If any adjustments are required STOP the engine first.

F

ENG 4-2

1

Make sure that the fan mounting hub is marked with reflective tape F.

2

Run the engine until it reaches operating temperature.

3

Run engine at maximum engine rev/min.

4

Measure the fan speed with the 8400 Venture Micro Digital Tachometer or similar hand held Tachometer.

5

Check that the recorded fan speed is as specified (see Technical Data this section).

6

If adjustment is required loosen locknut G. Turn set screw adjuster H with a 5 mm allen key. Turn counter clockwise to decrease fan speed and clockwise to increase fan speed. Tighten locknut G.

7

Run engine at maximum engine rev/min and measure the fan speed. If the fan speed is not correct stop the engine and remove the starter key, adjust as before.

A

G

H

S266411

Note: Adjuster H may be located as shown at A or B.

B

H G

A293420

9803/3630

Issue 1




www.maskinisten.net

Section E 16 - 1



16 - 1

S187390

9803/3630

Issue 1


Section E


16 - 2 *


16 - 2

Dismantling and Assembly Note: Before removing and dismantling the fan motor, check that its performance is as specified in Technical Data. If the motor performance is below that specified and the relief valve setting indicates internal leaks, the motor should be renewed. Renewal of components such as gears, bearings and housing will not effect a permanent cure. If the motor performance is satisfactory but there is external leakage, it should be dismantled for re-sealing only. Before dismantling make sure that the motor exterior and working area are thoroughly cleaned and free from possible sources of contamination.

Inspection 1

Inspect all 'O' ring grooves and shaft seal recesses in mounting flange 10. Make sure they are free from burrs.

2

Check that the mating faces of the end cover 6, body 20 and flange 10 are not scored.

3

The motor must be renewed if any of the following faults are found: a The PTFE coated bearing in the bushes are worn through so that the bronze base is visible.

Dismantling * Note: Nut 1, tab washer 2 and key 3 secure the fan and are removed when the motor is removed from the machine (see Fan Motor, Removal and Replacement). 1

Remove sharp edges and burrs from the drive shaft 14 to avoid seal damage.

2

Mark end cover 6, body 20 and flange 10 to ensure correct assembly.

3

Undo bolts 4 and spring washers 5 and remove end cover 6. Take care not to damage the machined faces by prising them apart - use a soft faced hammer.

b The gear side faces or bush faces are scored or chipped. c The drive shaft has a noticeable wear groove where the shaft seal lips run. *

d The stem of flow control valve 31 or the bore of flow control valve 32 seat is scored or chipped. e The check valve 23 seat is damaged.

* Assembly *1

Wash all components. Apply hydraulic oil immediately afterwards to prevent moisture collecting.

*2

Renew all seals and 'O' rings using JCB Special Hydraulic fluid as a lubricant.

*3

Fit shaft seal 22 into the mounting flange 10 with gaiter spring facing the motor. Fit circlip 21 and coat seal lips with JCB HP Grease.

Remove back-up seals 11, bush seals 12a and 12b and body 'O' ring 13.

*4

Remove drive shaft 14, bushes 15 and 16 and idler gear 17. Push out bushes 18 and 19 from the body. Note the position of bushes to ensure correct assembly.

Fit bushes 18 and 19 in their original positions. Place end cover 6 temporarily against main body 20 and stand assembly upright with dowels uppermost.

*5

Fit drive shaft 14 and idler gear 17. Fit bushes 15 and 16 in their original positions. Fit 'O' ring 13, bush seals 12a and 12b and back-up seal 11. Make sure that the flat face of back-up seal is uppermost.

*6

Fit protective sleeve 33 over drive shaft. Locate flange 10 to main body with a square fit on the dowels. Turn the assembly over and support on the flange, not on the drive shaft. Remove end cover.

*7

Remove flow control valve spring 30 and flow control valve 31.

Fit 'O' ring 9, bush seals 8a and 8b and back-up seal 7. Make sure that the flat face of back-up seal is uppermost. Fit end cover 6 with relief valve tapping on the same side as the outlet port. Secure with spring washers 5 and bolts 4. Torque tighten to 49Nm (36 lbf ft.).

* Note: Flow control valve seat 32 is retained in position by a locking sealant and should not be removed.

Continued...

4

Remove back-up seal 7, bush seals 8a and 8b, and body 'O' ring 9.

5

Remove flange 10, slide the flange off square to the shaft. Take care not to damage the machined faces by prising them apart - use a soft faced hammer to free flange from dowels.

6

7

8

Remove circlip 21 and shaft seal 22. Take care not to damage the shaft seal recess.

Note: Check valve assembly 23 is retained in position by a locking sealant and should not be removed. Remove only roll pin and ball. *9

* 10

Unscrew flow control valve spring retainer 24 along with hexagonal socket set screw 26 and lock nut 25. Unscrew set screw 26 and push out spring plug 27. Remove 'O' rings 28 and 29.

9803/3630

Issue 2*


Section E


16 - 3 *


16 - 3

Dismantling and Assembly (cont’d)

* Assembly (cont’d) 8

Put a small amount of clean hydraulic oil in the inlet port and check that the drive shaft can be turned by hand without undue force.

*9

Fit flow control valve 31 into valve seat 32. Fit 'O' ring 28 onto spring plug 27 and insert into spring retainer 24 along with spring 30. Fit 'O' ring 29 on spring retainer.

10

Screw spring retainer assembly into end cover 6 over relief valve. Torque tighten to 28Nm (20 lbf ft.). Fit set screw 26 and locknut 25.

* Note 1: Nut 1, tab washer 2 and key 3 secure the fan and are replaced when the motor is re-installed in the machine (see Fan Motor, Removal and Replacement). * Note 2: For flow control valve setting instructions, see Section E Contents. Torque Settings Item 4 24

Nm 49 28

kgf m 5.0 2.8

lbf ft 36 20

9803/3630

Issue 3*




www.maskinisten.net

Section E



Rams

30 - 1

30 - 1

*

J

H E F G

C

B

A A

D

Z

D

9803/3630

Issue 3*


Section E

www.WorkshopManuals.co.uk Hydraulics Rams

30 - 2


30 - 2

Lift Ram - 530, 540 Machines Removal Note: The illustration shows a typical machine. The procedure is the same for all machines above. 1

Remove any attachments from the carriage.

2

Support the boom as shown at Z.

3

Carry out General Safety Procedures, see Machine Safety, Section 3.

4


5

Support the lift ram A.

6

Remove nut and bolt B and withdraw the pivot pint C.

7

At this point it is advisable to remove the boom in order to provide access for lifting out the ram, see Body and Framework, Section B.

8

Attach suitable lifting equipment at the ram rod eye end. Support the ram.

9

Disconnect and plug lift ram hydraulic hoses D.

10

Remove the bolts E and F, spacer G and lock plate H. Withdraw the pivot pin J.

11

Remove the lift ram using lifting equipment.

Replacement Replacement is the reversal of removal. * Grease the pivot pins, see Service Schedules, Section 3.

9803/3630

Issue 4*


Section E



Rams

30 - 3

30 - 3

B L

J M G K

A G

B A

Z C D

F

E

H

H 345750

9803/3630

Issue 1


Section E


30 - 4


30 - 4

* Lift

Ram and Displacement Ram - 533, 535 Machines Removal 1

Remove any attachments from the carriage.

2

Support the boom as shown at Z.

3


4


5

Support the lift ram A and the displacement ram B.

6

Remove nut and bolt C and withdraw the pivot pin D from the lift ram A.

7

Remove nut and bolt E and withdraw the pivot pin F from the displacement ram B.

8

At this point it is advisable to remove the boom in order to provide access for lifting out the rams, see Body and Framework, Section B.

9

Attach suitable lifting equipment at the ram rod eye end of the lift ram. Support the ram.

10

Attach suitable lifting equipment to the piston end of the displacement ram. Support the ram.

11

Disconnect and plug lift ram hydraulic hoses G.

Note 1: The displacement ram hoses H will have been plugged during boom removal. 12

Remove bolt J and withdraw pivot pin K from the displacement ram.

13

Remove the displacement ram using suitable lifting equipment.

14

Remove lockbolt L and withdraw pivot pin M from the lift ram.

15

Remove the lift ram using suitable lifting equipment.

Note 2: Once the boom is removed, the lift ram or displacement ram may be left in position whilst the other is removed as required. Replacement Replacement is the reversal of removal. Grease the pivot pins, see Service Schedules, Section 3.

9803/3630

Issue 3*


Section E



Rams

31 - 1

31 - 1

A A

C

F B E

D

9803/3630

Issue 1


Section E


31 - 2


31 - 2

Displacement Ram - 530, 540 Removal 1

Lower the boom and carriage to the ground.

2

Carry out General Safety procedures, see Machine Safety, Section 3.

3


4

Disconnect and plug the displacement ram hydraulic hoses A.

5

Support the displacement ram F.

6

Remove lock bolt B and withdraw pivot pin C.

7

Remove lock bolt D and withdraw pivot pin E.

8

Remove the displacement ram F from the machine.

Replacement Replacement is the reversal of the removal procedure. Grease the pivot pins, see Service Schedules, Section 3.

9803/3630

Issue 1


Section E


33 - 1


33 - 1

E F

F

D D

C A

B

A294030

9803/3630

Issue 1


Section E


33 - 2


33 - 2

Extension Ram - 530, 540 Removal 1

Lower the boom and carriage to the ground. Remove any attachments from the carriage.

2

Extend the boom sufficiently to gain access to the extension ram rod end pivot pin A.

3

Carry out General Safety procedure, see Machine Safety, Section 3.

4


5

To gain access to the extension ram, remove the displacement ram, see Displacement Ram, this section.

6

Remove cap screw B, lock plate C and withdraw pivot pin A.

7

Disconnect and plug extension ram hydraulic hoses D.

8

Remove nut and bolt E. Remember that the pivot pin F is also the pivot for the boom. Use a dummy pivot pin to drive out the pivot pin F as far as the ram pivot. Then withdraw pivot pin F just far enough to release the ram.

9

Prepare suitable lifting equipment and withdraw the extension ram from the boom.


9803/3630

Issue 1


Section E


33 - 3


33 - 3

G JH

E

A D

B F

C

345800

9803/3630

Issue 1


Section E


33 - 4 * Extension


33 - 4

Ram (Outer) - 533, 535

Removal 1

Fully retract and lower the boom.

2


3


4

Clearly label and then disconnect feed hoses A and B and carry over hoses C and D. Plug the open ports.

5

Remove restraining strap E.

6

Support the extension ram.

7

Remove nut and bolt G and withdraw pivot F.

8

Remove snap ring J and withdraw pivot H.

9

Using suitable lifting equipment, remove the extension ram from the machine.

Replacement Replacement is the reversal of the removal procedure. Grease the pivot pins, see Service Schedules, Section 3. Bleed the boom extension circuit, see Boom Extension, Circuit Bleeding Procedure.

9803/3630

Issue 2*


Section E



Rams

34 - 1

34 - 1

E D G A

F

H

D H

B

C

9803/3630

Issue 2*


Section E


34 - 2 * Extension


34 - 2

Ram (Inner) - 533, 535

Removal

Replacement

The following procedure must be strictly adhered to, to prevent damage to the internal ram and auxiliary feed hoses.

Ensure the head side and rod side bushes are aligned before fitting the cylinder.

1

Park the machine on firm level ground. Apply the parking brake and remove the carriage.

1

Position the cylinder inside the inner boom.

2

Raise the boom to just above the horizontal. Extend the boom to gain access to the front pivot pin A.

2

Grease the rear pivot pin G. See Lubricants & Capacities (Section 3). Fit the pin and secure in place with bolt F.

3

Remove bolt B. Knock pin the through the boom using a drift.

3

4

Raise the boom and operate the retract control to slowly retract the extension ram. The inner boom section should retract with the hydraulic cylinder under its own weight.

Operate the extend control to slowly extend the cylinder and push out the inner boom section. Release the control when the front pivot pin is visible.

If the inner boom section will not retract under its own weight, lower the boom and carefully push the boom against an outside force (ie. another machine). Note: The length of the inner and intermediate boom sections protruding from the outer section must be kept equal to avoid damage to the internal hoses. 5

Lower the boom to align the inner ram rear pivot pin with the access holes C in the chassis.

6

Stop the engine and remove the starter key. Remove the hydraulic tank filler cap and operate the boom extend and retract controls to vent residual pressure.

7

Disconnect the hoses D from the rear of the extension cylinder. Plug the open ports and label the connections.

8

Move hoses E to one side of the boom to allow access to the inner extension ram.

9

Support the ram. Remove bolt F and knock pin G through the boom using a drift. Note the location of spacers H.

10

Carefully withdraw the ram from the boom using suitable lifting equipment. Take care not to damage any hoses inside the boom.

Note: The length of the inner and intermediate boom sections protruding from the outer section must be kept equal to avoid damage to the internal hoses. 4

Grease front pivot pin A. See Lubricants & Capacities (Section 3). Align the bush on the rod end of the cylinder with the boom. Fit the pin and secure in place with bolt B.

5

Connect hoses D at the rear of the extension cylinder.

6

Bleed the boom extension circuit. See Bleeding Boom Extension Circuit.

9803/3630

Issue 3*


Section E


35 - 1


35 - 1

B B C

D

E

E

F A

G

9803/3630

Issue 1


Section E


35 - 2


35 - 2

Tilt Ram - 530, 540 Removal 1

Remove attachments from the carriage.

2

Extend the tilt ram fully.

3

Extend the boom so as to gain access to cap screw A.

4

Lower the boom and carriage to the ground.

5

Carry out General Safety procedures, see Machine safety , Section 3.

6


7

Disconnect and plug tilt ram hydraulic hoses B.

8

Support the tilt ram E.

9

Remove bolt C and withdraw pivot pin D.

10

Remove cap screw A, lock plate F and withdraw pivot pin G, remove the ram from the machine.


9803/3630

Issue 1


Section E


35 - 3

E


35 - 3

D

C

B

C

A

345780

9803/3630

Issue 1


Section E


35 - 4 * Tilt


35 - 4

Ram - 533, 535

Removal 1

Extend the boom approximately 600 mm.

2

Lower the boom onto a suitable support so that the carriage is clear of the ground.

3

Stop the engine, remove the starter key and operate the controls to vent residual pressure.

4


5

Remove the recessed cap screw A.

6

Disconnect and plug tilt ram hydraulic hoses C.

7

Support the tilt ram.

8

Withdraw pivot pin B.

9

Undo and remove nut and bolt D and withdraw pivot pin E. Remove the ram from the machine.


9803/3630

Issue 2*


Section E



Rams

37 - 1

37 - 1

C B

D

A

B F

E

B

9803/3630

Issue 1


Section E


37 - 2


37 - 2

Sway Ram (if fitted) Removal 1

Lower the boom to the ground.

2


3


Note: There will still be residual pressure in the ram. This should be borne in mind if the ram is to be dismantled (see Typical Ram, Dismantling and Assembly). 4

Support the chassis on both sides of the machine.

5

Remove and plug the sway ram hydraulic hoses A.

6

Support the sway ram B.

7

Remove nut and bolt C and withdraw pivot pin D.

8

Attach suitable lifting equipment to the cylinder end of the ram. Support the ram.

9

Remove nut and bolt E and withdraw pivot pin F.

10

Lift the ram from the machine


9803/3630

Issue 2


Section E



Rams

38 - 1

38 - 1

C

C

G

F

D

E B

9803/3630

Issue 1


Section E


38 - 2 * Stabiliser


38 - 2

Rams - 533

Removal Note: The illustration and procedure describe removal of one stabiliser ram. The procedure for the second ram is identical. 1

Lower the boom to the ground.

2

Lower the stabilisers as far as the ground. Do not allow them to support the machine.

3

Carry out General Safety procedure, see Machine Safety, Section 3.

4


5

Disconnect the electrical socket B.

6

Remove and plug the stabiliser ram hydraulic hoses C.

7

Support the ram.

8

Remove nut and bolt D and withdraw pivot pin E.

9

Remove nut and bolt F and withdraw pivot pin G.

10

Lift the stabiliser ram from the machine.


Checking Pressure Switch Operation (if fitted) The pressure switches are pre-set and must not be adjusted. To check for correct operation, raise and lower each stabiliser in turn to ensure that the warning light illuminates when both stabilisers are making firm ground contact and extinguishes when one or both stabilisers are raised clear of the ground.

9803/3630

Issue 2*


Section E


39 - 1


39 - 1

Typical Ram - Fitting 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.

B

A

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.

C

D

Note: Later ram end caps and piston heads are 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 grooved and remove the tool.

5

Fit rod wiper seal P into seal groove. Make sure the seal is correctly installed as shown.

161750

P

Note: Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to ensure the seal is square before it is pressed in. Sleeve E must be used to protect the rod seals from damage when fitting end cap onto the piston rod. There are various sizes of sleeve, see Service Tools, Section 1. Make sure the hexagon on the end cap is towards the eye end of the rod.

Q 153212

E

9803/3630

A187361

Issue 1


Section E


39 - 2


39 - 2

Typical Ram - Fitting New Rod Seal (cont’d) Fit new piston seals: 6

Use a blunt instrument (Part no. 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 the O-ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, see Typical Ram Dismantling and Assembling.

9

Fit the piston head retaining dowel, see Typical Ram Dismantling and Assembling.

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 Typical Ram - Dismantling and Assembling for torque figure and completion of ram assembly.

H

338480

J

K

L 338490

9803/3630

Issue 1


Section E


40 - 1


40 - 1

Bleeding - Boom Extension Circuit 535 Machines Only)

* (533,

During the following procedure it is important that the internal ram is not allowed to extend more than the external ram, to prevent damage to the internal ram and auxiliary supply and return hoses. 1

A

Lift the boom to the horizontal position and support.

! CAUTION Allow the hydraulic fluid temperature to cool before removing the hydraulic tank filler cap. Open the cap slowly to prevent oil being forced out of the filler neck. 5-3-4-8

2 *3

Remove hydraulic tank filler cap. Earlier 535 machines Replace pressure test point adaptor A with tee adaptor 816/50029. Using a suitable length of 1/4” BSP hydraulic hose, attach one end to the replacement tee and route the other end back into the hydraulic tank.

A293740

533 and later 535 machines Fit a 3/8” hose, fitted with a female Quick Release Coupling (QRC) to the male QRC B and route the other end back into the hydraulic tank. 4

Start the engine and operate boom service to fully retract the inner boom. Very slowly extend the external extension ram fully. If whilst doing this the internal ram extends, operate the service to close the internal ram again. Repeat as necessary during the opening of the external ram.

5

With the external ram extended and the internal ram fully retracted hold the boom extension lever in the retract position until a steady flow of oil is obtained from the bleed hose. Return lever to the neutral position.

6

Detach the bleed hose from the coupling A and refit the hydraulic filler cap.

7

Hold the boom control lever in the retract position to fully close the external ram.

8

Extend and retract the boom fully 5 times whilst checking that the booms open and close fully together. Check all hydraulic connections are leak free.

9

If the booms do not open and close fully together repeat bleeding procedure.

B

A293741

9803/3630

Issue 4*




www.maskinisten.net

Section E 40 - 2



40 - 2

*

)

S257190

S314090

9803/3630

Issue 3*


Section E


40 - 3 *


40 - 3

Typical Ram Dismantling and Assembly

When Assembling

The illustration opposite shows a ram which is not fitted with a hose burst check valve (HBCV). If a HBCV is fitted the ram dismantling/assembly procedures are unaffected and can be carried out without the need to remove the check valve.

Fit new seals, ‘O’ rings and wear rings.

Note: Because the sway ram is fitted with HBCV’s to both sides, it is not possible to fully relieve system pressure prior to removal of the ram from the machine. The preferred method of releasing this residual pressure is by slow removal of end cap 8 which should precede HBCV removal.

Use JCB Cleaner and Degreaser to ensure that all threads are free from grease, hydraulic oil and old sealing/retaining compounds.

The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

Clean threads of piston rod, piston head, end cap and cylinder using a wire brush.

Ensure that lubricants used during assembly DO NOT come into contact with degreased components or sealing/retaining compounds. Ensure that seals or ‘O’ rings DO NOT come into contact with JCB Activator or anaerobic sealing and retaining compounds such as JCB Threadlocker and Sealer.

When Dismantling Place ram assembly on a locally manufactured strip/rebuild bench as shown. Use the correct size spanner to release end cap 8 and remove the piston rod assembly (items 1 to 12) from cylinder 19.

Make sure gland seals 10, 11 are correctly fitted as shown on the illustration. Use sleeve A to protect the gland seals from damage when fitting end cap 8 onto piston rod 12.

! 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.

A

HYD 1-2

Position piston rod assembly on bench in place of ram cylinder. Extract dowel 5 from the piston head using the appropriate sized screw threaded into the extractor hole.

S187360

Discard seals 2/3/10/11, ‘O’ rings 7/9 and wear rings 1/4. Continued on next page... Ensure that metal components are free from scoring, nicks and burrs. A damaged piston rod will impair the life of gland seals 10/11.

9803/3630

Issue 3*


Section E


40 - 4 *


Typical Ram (continued)

40 - 4

*

Dismantling and Assembly (cont'd) When Assembling (cont'd) Fit locking dowel 5 to piston 6 as follows: 1

Existing piston head and rod, align holes so that dowel can be fitted with tapped extractor hole showing.

2

New piston head and rod, drill and ream piston head and rod to the diameter and depth shown in the table. Remove all swarf and contamination and insert dowel with tapped extractor hole showing.

3

Existing piston head and new rod, drill through existing hole in piston head to the diameter and depth shown in the table. Remove all swarf and contamination and insert dowel with tapped extractor hole showing.

4

New piston head and existing rod, same as 2 above but at 90 degrees to existing hole in rod.

Note: Ensure that the top of the dowel is below the level of the bearing ring groove and use an undersized pilot drill before drilling to the final size shown in the table. Make sure when fitting piston seal 3 that it is correctly located and square in the piston head before fitting outer seal 2.

Ram size

Diameter X

Depth Y

90 x 50 100 x 60 110 x 60 120 x 60 130 x 70 130 x 75 140 x 75 160 x 80

8.10mm - 8.02mm 12.10mm - 12.02mm 12.10mm - 12.02mm 12.10mm - 12.02mm 12.10mm - 12.02mm 12.10mm - 12.02mm 12.10mm - 12.02mm 12.10mm - 12.02mm

28mm 33mm 33mm 38mm 38mm 38mm 48mm 48mm

Position cylinder 19 on the bench and install the piston rod assembly into the cylinder. Apply JCB Activator to threads of end cap and cylinder. Allow JCB Activator to dry for 15 minutes before bringing into contact with JCB Threadlocker. Apply JCB Threadlocker to threads of cylinder and torque tighten end cap 8. Note: If hydraulic oil contacts uncured locking fluid a weakening of the bond will result. Cure times vary according to the ambient temperature. The following approximate cure time applies at 20 degrees C and is the minimum period between assembly and filling the ram with oil. JCB Threadlocker & Sealer (High Strength) or JCB Threadlocker with JCB Activator - 1 hour. Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working. Torque Settings Item Nm 6 405 8 678

kgf m 41 69

lbf ft 300 500

9803/3630

Issue 4*


Section E


40 - 5


40 - 5

Extension Ram Make Up Valve Removal and Replacement Note: This valve is fitted to 3 stage boom machines only, and is assembled to the piston rod using locking fluid. With the valve removed check for freedom of movement of the plunger and ball. Renew 'O' ring seal. Thoroughly remove all oil, grease and dirt from threads of valve and piston rod. Apply JCB Activator and allow to dry for 15 minutes. Coat three central threads of the valve with JCB Threadlocker & Sealer (High Strength) ensuring that it does not contact 'O' ring seal. Re-assemble to piston rod ensuring that the end face is flush to 0.5 mm (0.02 in) below the end face of the piston rod as at X. Add washer 1410/0003 beneath valve if necessary. After assembly, plunger when pulled out, should protrude a minimum of 4 mm (0.16 in) from end face of piston rod as at Y. Note: Approximately 60 minutes should elapse from fitting the valve before allowing contact with hydraulic oil.

S159190

9803/3630

Issue 1




www.maskinisten.net

Section E


Section E www.maskinisten.net

Smooth Ride System (SRS)

41 - 1

41 - 1

Technical Data Gas: Capacity: Weight:

Air Free Dry Nitrogen 1 Litre (0.22 Gallon) 4.4 Kg (9.75 lb)

Accumulator Charge Pressure

Acc. No.

530 bar (psi)

540 bar (psi)

1

10.3 (150)

12.1 (175)

2

20 (290)

21.4 (310)

Note: Accumulators fitted to machines will have a label on the accumulator body specifying the charge pressure. Note: Replacement accumulators will only be supplied in an uncharged, non pressurised condition to meet Health and Safety/Airfreight hazardous goods requirements. Note: When replacing the lift ram or hose burst check valve on machines fitted with SRS, it is important that all the hydraulic pressure in the accumulators is vented (see Accumulators - Removal/Replacement on page 41-6). Failure to do this may result in the valve being forced out of the cavity as it is unscrewed.

9803/3630

Issue 1*


Section E


41 - 2



41 - 2

Description Smooth Ride System (SRS) will enhance the comfort of the ride by damping the forces imposed on the machine by the movement of the boom as the machine travels over uneven surfaces.

7

In order to engage the system, the lift ram must be fully closed or the weight of the boom must be supported. This is sensed by pressure switch 8. When the switch 7 in the cab is operated, and the pressure at the pressure switch 8 is less than 40 Bar (580 psi) the system is activated. Solenoid valve 3 is energised which lets oil flow from the piston head side of the lift ram 1 to the two accumulators 2. The rod side of the lift ram is connected to the valve block return line 6 via the solenoid valve 5 to make up or dissipate oil as required. For the electrical circuit and hydraulic system diagrams, see page 41 - 3. A356800

SRS System Key 1 2 3 4 5 6 7 8 9

1

2

Lift ram Accumulators Solenoid valve Valve block Solenoid valve Valve block return line On/Off switch Pressure switch Hose burst check valve

9 3 4

8

6

5

356810

9803/3630

Issue 1*



Section E



41 - 3

41 - 3

1

801HP

801GH

801GG

801GF

801GL

801GL

Electrical Circuit Diagram

2

1804B

1804A

11

1805A

1808D

3

1805

1805B

1804

4

5B

6A

1802

1800A

1800A

Accumulator Solenoid Drain Solenoid Diode Neutral relay Lift/lower micro-switch 5A Lift/neutral pole 5B Lower pole 6 Crowd/dump micro-switch 6A Neutral pole 6B Crowd/dump pole 7 Dump relay 8 SRS On/off switch 9 Pressure switch 10SRS relay 11SRS active warning light

6

5

5A

1 2 3 4 5

1803

1801

6B

1800A 1800B

7 1800A

1808

1800A

1800A

10 1800A

1800A

1808C

1800A

9

1800A

8

A356000 A356000

Hydraulic System Diagram

2A 1 3 2C 1 Valve block 2A Hose burst check valve 2B Solenoid valve 2C Pressure switch 3 Lift ram 4 Accumulators 5 Solenoid valve (chassis mounted) 6 Valve block return line

5

2B

6 4 A356010 A356010/1

9803/3630

Issue 1*


Section E


41 - 4


Section E www.maskinisten.net 41 - 4

Fault Finding

1

Fault

Probable Cause

System will not activate

Excessive pressure in lift ram Faulty pressure switch

2

Ensure weight of boom is fully supported when activating system Check switch. Replace as necessary

Unable to lower the boom

Rod side (drain) solenoid valve open

Check if solenoid operating, replace as required Check electrical feed to solenoid/switch back of lift spool

Restricted boom suspension movement when system switched ON

Rod side solenoid valve closed.

Check if solenoid operating, replace as required Check electrical feed to solenoid/switch

on 3

Action

on back of tilt spool 4

Springy boom operation with system switched OFF

Head side (accumulator) solenoid valve open.

Check if solenoid operating, replace as required

5

No suspension when system switched ON

Electrical supply problem.

Check fuse 31 Check for continuity in wiring Check if solenoid operating, replace as required Check electrical feed to solenoid/switch

Head side solenoid valve closed

on back of lift spool 6

Suspension feels ‘hard’ (gas charge pressure increase)

Oil to gas leak across accumulator Discharge, drain and recharge. If frequent, piston replace seals in accumulator

7

Suspension feels ‘soft’ (gas charge pressure decrease)

Leak across accumulator piston.

Recharge. If frequent, replace seals in accumulator

Check fuse 31 (5A) replace as required. Note: The system will not engage until the lift ram is fully closed or the weight of the boom is fully supported.

9803/3630

Issue 1*


Section E




41 - 5

41 - 5

Accumulators Charging

Discharging

1

Remove the accumulator(s) from the machine, see page 41 - 6.

1

Remove the accumulator(s) from the machine, see page 41 - 6.

2

Remove gas valve guard A and gas valve cap B.

2

Remove gas valve guard A and gas valve cap B.

3

Screw valve C all the way out (counter clockwise) before attaching charging tool (part no. 892/00948) to accumulator gas valve.

3

Screw valve 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

Do not twist the hose, connect the charging tool to the gas valve. Tighten to 1.36 Nm (1.0 lbf ft).

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 valve C all the way in (clockwise), this will depress the core in the gas valve.

7

Open bleed valve D until all the gas charge is relieved from the accumulators. Remove the charging tool.

8

Install the accumulator(s) to the machine, see page 41 - 6.

7

Screw valve 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 boom and the attachment fitted to the machine. For recommended pressures see Technical Data.

8

If charge pressure is low, release hand valve E on the nitrogen bottle and SLOWLY fill the accumulators. 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 accumulators. HYD 2-4

10

When complete screw valve C all the way out (counter clockwise) then open the bleed valve D to vent the hose.

11

Hold the gas valve to keep from turning, loosen the nut and remove charging tool.

12

Refit gas valve cap and valve guard.

13

Install the accumulator(s) to the machine, see page 41 - 6.

A B D

F

E

C

S308270

9803/3630

Issue 1*


Section E




41 - 6

41 - 6

Accumulators Removal

Replacement

! CAUTION

Replacement is a reverse of removal.

You must vent all the hydraulic pressure from the accumulators before disconnecting them from the hydraulic system.

Charge the system as detailed on page 41 - 5.

0043

Check for correct operation and leaks. Replenish the hydraulic system with the recommended hydraulic fluid as required.

1

Switch off the SRS and lower the boom to the ground.

2

Power the boom down for three minutes with the engine at approximately 1000 rev/min. The accumulators will gradually drain to tank during this time.

3

Raise the boom and install the safety strut, see ‘Routine Maintenance’ in section 3.

4

Loosen the four nuts 2.

5

Disconnect hydraulic connections 1 and plug the ends.

6

Remove the four nuts 2 and four washers 5 and remove the two ‘U’ clamps 3. Remove the accumulators 4 from their mounting brackets.

3

4

3

1

4

5 2

5 2

356820

9803/3630

Issue 1*


Section E




41 - 7

10

9

41 - 7

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

9803/3630

S308280

Issue 1*


Section E




41 - 8

41 - 8

Accumulators Inspection Note: This procedure tells you how to dismantle, inspect and assemble one of the accumulators. The other accumulator is maintained in the same way.

Dismantle

!DANGER Discharge all gas pressure before dismantling the accumulators. 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. 0044

Inspect piston for cracks, burrs around the ‘O’ ring grooves, or damage. Examine the body bore 1, using a light, for scratches or scoring. Inspect end caps for damaged threads or burrs on ‘O’ ring grooves. Minor nicks, scratches or light scoring of the body bore may be removed by using a very fine paper. Dress the bore until all apparent imperfections have been removed. All seals and ‘O’ rings must discarded and new ones fitted.

Assembly

1

Check that the accumulator you are working on has been discharged, see page 41 - 5.

1

Coat all internal components with clean hydraulic oil.

2

Secure the accumulator in horizontal position.

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.

! CAUTION The gas end cap (cap with gas valve) must be removed before the hydraulic end cap. This allows any residual pressure to escape through the safety vent holes. If the hydraulic end cap is removed first the piston will cover the safety vent holes, which could result in the piston being forced out under pressure which may result in personal injury. HYD 2-6

3

Fit three pins into the holes in gas end cap 4, using a long bar working against the pins unscrew the end cap.

4

Fit three pins into the holes in hydraulic end cap 5, using a long bar working against the pins unscrew the end cap.

5

Remove and discard ‘O’ rings and back up rings from end caps.

6

Remove the piston 6 by pushing from the hydraulic end with a bar.

! CAUTION Do not remove the piston by applying compressed air at the opposite end.

Note: Keep pressure on the piston while tapping through the bore chamfer, otherwise the piston will bounce back, damaging the piston ring. 4

Fit end cap back up seal 7. Make sure the seal is fitted with leading edge A pointing in a counter clockwise direction otherwise the seal will bind when the end cap is fitted.

5

Fit end cap ‘O’ rings 8, it is important that seals 7 and 8 are fitted in the correct position in relation to each other to prevent leaks.

6

Fit end caps 4 and 5, use pins and a long bar. Make sure the gas end cap is fitted to the correct end, piston hollow end to gas side.

Note: The end caps will stop against the chamfer leading into the honed bore, ‘O’ ring sealing is not dependent upon cap tightness.

HYD 2-7

7 7

Use new ‘O’ ring 13 and fit the gas valve 12.

Remove piston seal and ‘O’ rings.

9803/3630

Issue 1*


Section E



Parallel Lift

51 - 1

51 - 1

Boom Raise Cycle When lift spool 2D is selected, the neutral circuit is blocked and oil feeds lift ram hose-burst check-valve 8A. Oil flows through free flow direction of hose burst check valve (HBCV) 8A and lifts the boom.

Displacement/lift link valve 20 is fitted between lift spool 2D and tilt spool 2F. The function of this valve is to allow a restricted flow of oil into the tilt circuit to increase the lift force available by utilising the compensating ram.

Oil is forced out of the head side of displacement ram 9 as the boom rises. The oil cannot flow past the tilt spool 2F, as the spool is not selected. Instead, it flows to the head side of tilt ram 10. Oil displaced from the rod side of the tilt ram raises pilot pressure in HBCV 10A. This allows oil to feed back to the rod side of the compensating ram.

Auxiliary relief valve (ARV) 2J opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2H ensures that, in these circumstances, the tilt and compensating rams will not cavitate.

This has the effect of allowing the tilt ram to extend in proportion to boom lift, keeping the forks parallel with the ground.

A

2F

B

T 2H

2J A

2D

B

e w

9

10A 10

P

20

8 416480

8A

e

9803/3630

Issue 1


Section E



Parallel Lift

51 - 2

51 - 2

Boom Lower Cycle When raise/lower spool 2D is selected, the neutral circuit is blocked and oil feeds the rod side of lift ram 8. Oil displaced from the head side of the lift ram raises pilot pressure in HBCV 8A and allows oil out of the lift ram back to tank, lowering the boom.

Displaced oil from the compensating ram closes the check valve in displacement/lift link valve 20. Auxiliary relief valve (ARV) 2H opens to protect the tilt ram from over pressurisation. The anti-cavitation feature of valve 2J ensures that, in these circumstances, the tilt and compensating rams will not cavitate.

As the boom lowers, oil is forced from the rod side of the displacement ram 9. The oil cannot flow past tilt spool 2F, as the spool is not selected. Instead, it flows through free flow direction of HBCV 10A to the rod side of the tilt ram 10. This has the effect of allowing the tilt ram to retract in proportion to boom lower, keeping the forks parallel with the ground.

A

2F

B

T 2D

2H

2J A B

w 9

e

10A 10

P

20

8 416490

8A

w

9803/3630

Issue 1


Section E


51 - 3


Parallel Lift

51 - 3

Fault Finding Note: The forks will continue to crowd back when the boom reaches maximum elevation angle, if the lift lever is NOT deselected on machines fitted with displacement link valve 20. This is normal and is caused by oil bleeding from the lift circuit to the tilt circuit.

PROBLEM

POSSIBLE CAUSE

REMEDY

Forks creep down

Circuit hosed incorrectly. Has any work been completed on the machine recently?

Check circuit. Re-route the hoses if necessary.

Tilt ram HBCV leaking, tilt ram seals leaking, control valve spool leaking or valve block section leaking internally.

Check for leakage in the tilt ram circuit.

Displacement/lift link valve broken or leaking.

Examine valve; is ball OK? Fit blank to isolate valve from circuit.

Parallel lift faulty

Fit latest type valve. Check pipes, tilt spool, HBCV for missing ball. Tilt section ARVs 2H or 2J set incorrectly, causing oil to exit from tilt/compensating ram circuit.

Check tilt ARV setting. Adjust if required.

Tilt section ARVs 2H or 2J could be sticking open due to contamination.

Clean or new as required.

Leaking seals in tilt ram 10 or compensation ram 9.

Check tilt/compensation rams for leakage (use hand pump if available). Renew seals as required.

9803/3630

Issue 1




www.maskinisten.net

Section F

www.WorkshopManuals.co.uk Transmission

i

www.maskinisten.net Section F

i

Contents

Page No.

Technical Data

1-1

General Description

1-4

Towing Procedure

2-1

Powershift Transmission - General Description - 4 Speed 3-1 - General Description - 5 Speed 3-3 - Drive Paths 3-5 - Fault Finding 4-1 - Removal and Replacement 5-1 - Summary of Changes - 4 Speed 5-3 - PS700 - 4 Speed Section Views and Torque Figures 5-4 - PS750 - 4 Speed Section Views and Torque Figures 5-7 - PS750 - 5 Speed Section Views and Torque Figures 5 - 10 Powershift, 4 Speed (With Reverser Shaft Cover Plate) - Dismantling 6-1 - Assembling 7-1 Powershift, 4 Speed (With Reverser Shaft Plug & PS750) - Component List 8-1 - Dismantling 8-3 - Assembling 9-1 Powershift PS750, 5 Speed - Component List 10 - 2 - Dismantling 10 - 3 - Assembly 11 - 1 Powershift PS700 - Input and Reverser Clutch Location of Components 12 - 1 Dismantling 12 - 5 Assembly 12 - 8 - Mainshaft Location of Components 12 - 11 Dismantling 12 - 13 Assembly 12 - 16 - Layshaft Location of Components 12 - 19 Dismantling 12 - 21 Assembly 12 - 24 Powershift PS750 - Input and Reverser Clutch (4 Speed) Dismantling 13 - 1 Assembly 13 - 3 - Input Clutch ( 5 Speed) Dismantling 13 - 4 Assembly 13 - 6 - Mainshaft Dismantling 14 - 1 Assembly 14 - 3 - Layshaft Dismantling 15 - 1 Assembly 15 - 3

9803/3630

Issue 5


Section F


ii


ii

Contents

Page No.

- 5th Speed Clutch Dismantling 15 - 4 Assembly 15 - 8 Powershift Transmission - Hydraulic 2/4 Wheel Drive Unit Dismantling and Assembly 16 - 1 Pressure Testing the 2/4WD Clutch 16 - 4 - Permanent 4 Wheel Drive Unit Dismantling and Assembly 16 - 5 - Solenoid Valve - Dismantling and Assembly 16 - 7 - Polytetrafluoroethene (PTFE) Piston Ring Seals - Fitting Procedure 16 - 8 - Collapsible Spacer - Assembly 16 - 9 - Output Shaft Removal (Larger Diameter Gear) 16 -10 - Solenoid Identification 17 - 1 - Torque Converter Stall Test 17 - 2 - Clutch Leakage Testing 17 - 3 - Pressure and Flow Testing 17 - 4 - Flushing the Transmission Oil 17 - 12 - Transmission Oil Cooler - Removal, Testing and Replacement 17 - 13 Torque Converter - Removal and Replacement

18 - 1

Bevel Gear Box - Removal and Replacement - Oil Seal Renewal - Dismantling - Assembly

19 - 1 20 - 1 20 - 3 20 - 5

Propshafts

21 - 1

Axles - General Description - Front Fixed Axle (SD70) - Removing and Replacing - Front Sway Axles (SD70), (USA only) - Removing and Replacing - Rear Axle (SD55) - Removing and Replacing Front Axle (SD70) - Hub - Dismantling - Hub - Assembly * - Brakes (Without Controlled Back-off) - Dismantling and Assembly - Brakes (With Controlled Back-off) - Dismantling and Assembly - Drive Head - Dismantling and Assembly

22 - 1 22 - 2 22 - 4 23 - 1

24 - 1 24 - 3 24 - 7 24 - 9 26 - 1

9803/3630

Issue 5*


Section F


iii


iii

Contents Rear Axle (SD55) - Hub Dismantling and Assembly - Drive Head Dismantling and Assembly

Page No.

29 - 1 30 - 1

Crownwheel and Pinion - Adjustment

33 - 1

Limited Slip Differential Option (SD70)

36 - 1

Salvage and Repair - Introduction - Drive Shaft Outer Oil Seal - Variants - Drive Shaft Inner Oil Seal - Variants - Drive Shaft - Salvage After Oil Seal Failure - Axle and Gearbox Drive Shaft Flange - Salvage After Oil Seal Failure - Hub Bearing Carrier Oil Seal - Variants * - Renewing the Pinion Oil Seal - Fitting a New Spacer to Drive Head

45 - 1 45 - 2 45 - 3 45 - 4 45 - 5 45 - 7 45 - 8 45 - 10

9803/3630

Issue 2*




www.maskinisten.net

Section F



Technical Data

1-1

1-1

Powershift * Description

Full electro-hydraulic transmission 4 or 5 speed (3 Germany) unit with input, layshaft, mainshaft, reverse, 5th gear (if applicable) and 4 wheel drive clutch packs.

Designation

PS700 or PS750

Weight (dry)

2WD 4WD

157 kg (346 lb) 176 kg (388 lb) Extra Low Ratio 1.495

Std Ratio 1.307

Input Gear Output Gear

21 44

23 44

4 Speed 279mm (11in) 2.20:1 Ratio 2 purple/1 White

5 Speed 310mm (12.2in) 2.24:1 Ratio 2 Blue

1000 rev/min 2000 rev/min

bar 2.8 - 4.1 4.8 - 6.2

kgf/cm2 2.8 - 4.2 4.9 - 6.3

lbf/in2 40 - 60 70 - 90


1.9 - 2.3 2.3 - 2.7

1.9 - 2.3 2.3 - 2.7

27 - 33 33 - 39

Converter Relief (Safety) Valve Setting

6.5

6.7

95

Lubrication Pressures (in neutral) At 50 deg.C


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


bar 9.0 - 10.0 9.7 - 11.0

kgf/cm2 9.1 - 10.2 9.8 - 11.3

lbf/in2 130 - 145 140 - 160


litres/min 10.4 - 13.6 14.5 - 20.0

US gal/min 2.8 - 3.6 3.8 - 5.3

UK gal/min 2.3 - 3.0 3.2 - 4.4


11.0 - 15.0 22.5 - 29.5

2.9 - 4.0 6.0 - 7.8

2.5 - 3.3 5.0 - 6.5

2/4 Wheel Drive Ratio 4 Wheel Drive Number of Teeth

Torque Converter Dia. Torque Converter Colour Coded Dots

Converter Pressures (in neutral) Converter In at 50 deg.C

Converter Out at 50 deg.C

Mainline Pressure (in neutral) At 50 deg. C

Flow Rates (in neutral) Cooler at 50 deg.C

Pump at 50 deg.C

All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2). 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 ).

9803/3630

Issue 5*


Section F



Technical Data

1-2

1-2

Front Axle Type Brakes Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction

JCB SD70. Spiral bevel with epicyclic hub reduction Oil immersed multi-plate disc located in centre section Powered track rod mounted on rear of axle Standard 15.78:1 Standard 2.923:1 Extra Low 3.364:1 5.4:1

Extra Low 18.16:1 Colour Code: Orange Colour Code: Blue

Rear Axle Type Steering Weight (approximate) Overall Gear Ratio Crownwheel and Pinion Ratio Hub Reduction

JCB SD55. Spiral bevel with epicyclic hub reduction Powered track rod mounted on rear of axle 23.62:1 4.375:1 5.4:1

Colour Code: Blue

Tyre Pressures Front

Rear

Ply

Bar

lbf/in2

Bar

lbf/in2

Manufacturer/Type

530 (Not Super Models): 17.5 - LR 24 15.5/80 - 24 10 15.5-25 12 12.00 R24 X MINE D2 ----

3.7 4.0 4.0 4.0

53 58 58 58

3.7 4.0 4.0 4.0

53 58 58 58

Traction Sure Grip/Traction Industrial Traction

4.0 4.0 4.0 4.0

58 58 58 58

4.0 4.0 4.0 4.0

58 58 58 58

Industrial Traction Sure Grip/Traction Traction

53 58 53

3.7 4.0 3.7

53 58 53

Traction Traction Traction

Size

* 533, 535, 540 (Not Super Models): 15.5-25 12 15.5/80 - 24 10 445/70 R24 XM47 ---12.00 R24 X MINE D2 ----

530FS Super, 540FS Super, 530 SXL, 540 SXL 440/70 R24 XM37 -3.7 445/70 R24 XM47 -4.0 500/70 R24 XM37 -3.7

Note: The maximum pressure embossed on the tyre may differ from the pressure stated above. Inflate to pressures above, these are agreed with the tyre manufacturer/s in accordance with the European Tyre and Rim Technical Organisation (ETRTO) standards to satisfy machine stability performance. If the tyres fitted to your machine are not listed, contact your JCB Distributor for advice, DO NOT guess tyre pressures. IMPORTANT: Ensure the correct tyres are fitted and inflated to the recommended pressure before towing with a 535 machine. Check the load charts in the cab for the correct tyre and pressure. General Description The front axle consists of a centre casing (drivehead) and two axle arms. The drivehead houses the differential gearing and two oil-immersed disc brake units. The axle arms house the halfshafts. Specially shaped spider gears in the differential provide 'torque proportioning'. This means that drive power will be kept on one wheel if the other is slipping. The wheel hubs are connected to the halfshafts through universal joints which drive sun-and-planet gears inside the hubs. The rear axle works on the same principle as the front axle, but has a single-piece casing which houses the differential and halfshafts. The axle is unbraked. The rear axle is mounted to the machine through a horizontal trunnion. This allows the wheels to ride up and down over uneven ground, helping to keep the machine, and its load, level. The front axle is rigidly mounted to the chassis or if a sway machine through a horizontal trunnion. 9803/3630

Issue 5*


Section F



Technical Data

1-3 * Pump/Transmission

1-3

Stall Speed Combinations - 11 inch & 12.2 inch Converters

The figures given below and on the following page apply to ‘bedded-in’ engines. ie. engines that have done a minimum of 250 working hours, therefore they should not be used for pre-delivery inspection (PDI) checks. They are intended to be used as guideline figures only and should not be considered as servicing parameters. All figures are recorded with the machine at operating temperature - transmission oil at 60°C (140°F), hydraulic oil at 55°C (131°F). JCB Diesel Engines - Build Codes AA and AB Torque Converter Stall 106 hp Turbo (rpm) 76 hp NA (rpm) Combined Stall 106 hp Turbo 76 hp NA

(rpm) (rpm)

Pump Size (l/min)

1960 1685

1280 1185

82

Converter Type (11in)

2.2:1

* JCB Diesel Engines - Build Codes AM Torque Converter Stall 120 hp Turbo intercooled (rpm)

1980

Hydraulic Stall 120 hp Turbo intercooled (rpm)

2320

Combined Stall 120 hp Turbo intercooled (rpm)

1620

Pump Size (l/min) Converter Type (12.2in)

82 2.24:1

* JCB Diesel Engines - Build Codes AK and AR Torque Converter Stall 102 hp Turbo (rpm) 80 hp NA (rpm)

1950 TBA

Hydraulic Stall 102 hp Turbo 80 hp NA

(rpm) (rpm)

2280 TBA

Combined Stall 102 hp Turbo 80 hp NA

(rpm) (rpm)

1620 TBA

Pump Size (l/min) Converter Type (11in)

82 2.2:1

Note: Combined stall tests are performed with the crowd service operated until the relief valve is lifted. Figures achieved should be within ± 100 rpm from figures quoted above.

9803/3630

Issue 4*


Section F


1-4

*

General Description


1-4

The transversely mounted engine A drives a permanently engaged 90° bevel gearbox B. A torque converter is mounted on the output end of the bevel gearbox at C. The output from the torque converter drives an electro hydraulically controlled (Powershift) gearbox D (see separate description). Drive from the gearbox is transmitted to the steer drive front axle E and to a steer drive axle F, at the rear, via propshafts G. The bevel gearbox and Powershift gearbox share the same lubricating oil. The transmission features dedicated oil filtering and cooling systems. A disc type parking brake H is fitted at the gearbox end of the front axle propshaft. Drive is taken from the bevel gearbox to the hydraulic pump J via a short splined tube. The engine incorporates a vibration damper bolted to the flywheel at K.

K

F

A

J C

H G

B

G

D

E S296950

9803/3630

Issue 3*


Section F

www.WorkshopManuals.co.uk Transmission Towing Procedure

2-1


2-1

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 and that the 2/4WD selector is in the 2WD position. Restrict recovery speed to 25 k.p.h. (15 m.p.h.). If it is necessary to recover the machine for a distance in excess of 1.5 kilometres (1 mile) the front propshaft should be disconnected to prevent damage to the transmission system.

! 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. Trans 1-3

Position the machine on firm level ground and block the wheels securely to prevent any movement. Select neutral and release the parking brake. Disconnect the front propshaft from the axle and tie up the shaft securely well clear of the rotating axle flange. Alternatively remove the shaft completely. Connect the recovery vehicle via the towbar BEFORE removing the blocks from the wheels. Restrict the recovery speed to 25 k.p.h. (15 m.p.h.). When recovery is complete, block the wheels securely BEFORE removing the towbar and reconnecting the propshaft. Important: In some countries the above procedures may not be legally acceptable for recovery on public highways.

9803/3630

Issue 1



3-1

Powershift Transmission S141911

3-1

www.WorkshopManuals.co.uk Transmission *

Section F

Issue 2*

9803/3630


*

9803/3630


Input/forward 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.

The torque converter is a fluid coupling bolted to a drive plate which in turn is bolted to the bevel gearbox output shaft. 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.

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.

Some machines (refer to Electronic Control Unit, Section C for details) are fitted with an Electronic Control Unit (ECU) Q. The ECU when fitted, is designed to control the selection of gears and direction.

Filter P is used to prevent potential system contamination by filtering dirt particles. On 530 machines filter P is fitted under the chassis.

The 2/4 wheel drive unit also has a single clutch. In normal operation the clutch is spring-loaded and therefore engaged to give 4 wheel drive. When 2 wheel drive is selected, solenoid valve N is energised and directs pressurised oil to the 2/4 wheel drive clutch. The pressurised clutch 'deselects' the transmission to 2 wheel drive.

Note: Some machines are fitted with a 2-position solenoid valve M. When de-energised, pressurised oil is supplied to the mainshaft clutch and when energised, to the layshaft clutch. Since there is no neutral position, either the mainshaft or layshaft is always engaged.

Both the mainshaft and the layshaft assemblies have a single clutch each. A 3-position solenoid valve M, supplies pressurised oil to either the mainshaft clutch or the layshaft clutch.

Drive to the reverse clutch assembly C is transmitted via constant meshing of spur gears Z.

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.

Q

A263030

CE

For testing and electrical circuit, see Section C, Contents.

The unit receives signals from the gear and direction selection and operates the appropriate gearbox solenoids accordingly.

It is a microprocessor controlled unit which is mounted over the gearbox solenoid valves. A cable harness connects the ECU to the solenoids and the gearbox oil pressure switch. The chassis harness, connector CE, provides the input signals, see Section C.

3-2

A combined lever/swivel switch on the steering column actuates both gear ratio and direction solenoids.

Electrically operated solenoid valves divert pressurised oil (provided by pump Q) to the selected clutch packs.

The unit is available with selectable 2/4 wheel drive, or with permanently engaged 4 wheel drive. The descriptions and dismantling/assembly procedures include the 2/4 wheel drive unit. Transmissions with permanently engaged 4 wheel drive do not have a 2/4 wheel drive clutch at F, or a control solenoid valve N.

The JCB Powershift is an electro-hydraulic transmission unit. Gear shifting and direction selection are controlled using multi-disc clutch packs.

General Description - 4 Speed

Section F

www.WorkshopManuals.co.uk Transmission www.maskinisten.net Section F

Powershift Transmission 3-2

Issue 4*

Section F



Powershift Transmission

3-3

3-3

W

*

N

G M L P Z K Q

H

S296931

B D

R

E

Z

C

F

9803/3630

A362650

A362650

Issue 3*


Section F




3-4

3-4

General Description - 5 Speed The JCB Powershift is an electro-hydraulic transmission unit. Gear shifting and direction selection are controlled using multi-disc clutch packs. Electrically operated solenoid valves divert pressurised oil (provided by pump Q) to the selected clutch packs.

Drive paths and engaged clutches for various gear ratios are illustrated in Drive Paths. Note that not all possible drive paths are shown and that 5th gear is available in forward drive only.

A combined lever/swivel switch on the steering column actuates both gear ratio and direction solenoids.

Machines are fitted with an Electronic Control Unit (ECU) 1. See Electronic Control Unit (ECU) - Five Speed Transmission (Section C). The ECU is designed to control the selection of gears and direction.

The Powershift unit consists of a torque converter, input clutch assembly B, reverse clutch assembly C, layshaft assembly E, mainshaft assembly D, 5th speed clutch assembly P, 2/4 wheel drive clutch assembly F and a parking brake disc mounted on splined output shaft K.

It is a microprocessor controlled unit which is mounted under the driver’s seat. A cable harness connects the ECU to the transmission solenoids, oil pressure switch and speed sensor. The mainframe harness connector 2 (36 pin) provides the input signals.

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 4 speed clutch/gear assemblies via input shaft H.

The unit receives signals from the gear and direction selection and operates the appropriate transmission solenoids accordingly.

Input forward 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.

For testing and electrical circuit, see Section C, Contents.

1

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.

2

Drive to the reverse clutch assembly C is transmitted via constant meshing of spur gears Z.

A362650

Both the mainshaft and the layshaft assemblies have a single clutch each. A 3-position solenoid valve M, when energised, supplies pressurised oil to either the mainshaft clutch or the layshaft clutch. The 5th gear driveshaft P is permanently driven from the engine via the torque converter outer case and splined gear R. When the 5th gear is selected a solenoid valve W is energised and directs pressurised oil to the 5th gear clutch P. A speed sensor is used to inhibit selection of the 5th gear if the machine road speed is too low. 5th gear is not available in reverse. The 2/4 wheel drive unit also has a single clutch. In normal operation the clutch is spring loaded and therefore engaged to give 4 wheel drive. When 2 wheel drive is selected, solenoid valve N is energised and directs pressurised oil to the 2/4 wheel drive clutch.

X

Filter X is used to prevent potential system contamination by * filtering dirt particles.

9803/3630

A372830

Issue 4*


Section F




3-5

3-5

Note: The illustration shows a 5-speed gear box. 5th gear clutch P , its associated drive shaft S and 5th gear solenoid Q are fitted to 5-speed gearboxes only.

Q G1

All other components are similar and drive paths for 1st to 4th and reverse gears are identical in both 4- and 5-speed gearboxes. 5th gear is available in forward gear only.

N

M1

L1

P

L2 S

G2

M

S296931

B2

D

B1 E

C2 A362650

F C1 9803/3630

Issue 1




www.maskinisten.net

Section F




3-6

3-6

Drive Paths Figure 1 - 1st GEAR FORWARD (4 Wheel Drive)

Figure 4 - 4th GEAR FORWARD (4 Wheel Drive)

Clutches Engaged

Clutches Engaged

B1 E F -

B2 D F -

Forward Low Ratio Layshaft 2/4 wheel drive (spring loaded)

Forward High Ratio Mainshaft 2/4 wheel drive (spring loaded)

Solenoids Active

Solenoids Active

B2

B1

G1 M1 (if fitted)

G2 M

D

E F

F

A265621 A255470

Figure 2 - 2nd GEAR FORWARD (4 Wheel Drive)

Figure 5 - 1st GEAR FORWARD (2 Wheel Drive)

Clutches Engaged

Clutches Engaged

B2 E F -

B1 E -

Forward High Ratio Layshaft 2/4 wheel drive (spring loaded)

Forward Low Ratio Layshaft B1

Solenoids Active Solenoids Active

B2

G2 M N 2/4 wheel drive

G1 M

E E

F A255510

A255480

Figure 3 - 3rd GEAR FORWARD (4 Wheel Drive)

Figure 6 - 1st GEAR REVERSE (4 Wheel Drive)

Clutches Engaged

Clutches Engaged

B1 D F -

C1 E F -

Forward Low Ratio Mainshaft 2/4 wheel drive (spring loaded)

Solenoids Active

Solenoids Active

B1

G2 M1 (if fitted)

Reverse Low Ratio Layshaft 2/4 wheel drive (spring loaded)

L1 M

D

E

F

F C1 A255490

9803/3630

A255520

Issue 1


Section F

www.WorkshopManuals.co.uk Transmission Powershift Transmission

3-7


3-7

Drive Paths (continued) In 5-speed gearboxes, the 5th gear drive shaft S is permanently driven by a direct drive from the torque converter outer case E. Figure 7 - 5th GEAR FORWARD (2 Wheel Drive) Clutches Engaged D - Mainshaft P - 5th Speed Solenoids Active Q - 5th Speed N - 2/4 wheel drive

P

S E

D

A362041 A362041

Figure 8 - 5th GEAR FORWARD (4 Wheel Drive) Clutches Engaged D - Mainshaft P - 5th Speed F - 2/4 wheel drive (spring loaded)

Solenoids Active Q - 5th Speed

P

S E

D

F

A377880 A377880

9803/3630

Issue 1


Section F


4-1

*



4-1

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.

Many types of faults can be caused by the above. In particular see the fault finding section on oil contaminated with water. * For checking the electronic control unit (ECU) on ECU controlled transmissions, see Section C, Contents.

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:

Index Lack of Power Low Mainline Pressure High Stall Speeds (On All Clutches) Low Stall Speeds (On All Clutches) Low Converter Out Pressure Low Pump Flow High Converter Out Pressure Low Lubrication Pressure Overheating 2WD Cannot be Engaged Transmission Oil Contaminated with Water

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.

LACK OF POWER Possible Cause 1 2 3 4 5 6 7 8 9 10 * 11

Remedy

Poor engine condition. Low oil level. Worn pump. Torque converter damage. Low mainline pressure. Clutches slipping. Internal leakage. High stall speeds. Low stall speeds. Overheating. Converter relief valve faulty.

*

1 2 3 4 5 6 7 8 9 10 11

Check and if necessary repair engine. Top up system. Check and if necessary repair or renew pump. Check and if necessary repair or renew torque converter. See fault 'Low Mainline Pressure'. Check clutch pressures, check clutch piston rings. Check internal cored galleries and the casting for porosity. See fault 'High Stall Speeds (on ALL clutches)'. See fault 'Low Stall Speeds (on ALL clutches)'. See fault 'Overheating'. Check and if necessary repair relief valve.

LOW MAINLINE PRESSURE Possible Cause

Remedy

1 2 3 4

Worn pump. Blocked suction strainer. Pressure maintaining valve sticking/leaking. Oil aerated (foaming).

1 2 3 4

5

Oil leak thru' 2/4WD circuit.

5

HIGH STALL SPEEDS (ON ALL CLUTCHES) Possible Cause 1 2 3 *4

Damaged converter blades. Clutches slipping. Internal leakage. Converter relief valve faulty.

Check and if necessary repair or renew pump. Clean suction strainer. Free off or renew valve. 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. a) Check external pipework for 2/4WD circuit. b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel drive clutch fault finding procedure.

Remedy

*

1 2 3 4

Check and if necessary repair or renew converter. Strip, inspect and fit new clutch friction/counter plates. Check internal cored galleries and the casting for porosity. Check and if necessary repair relief valve.

LOW STALL SPEEDS (ON ALL CLUTCHES) Possible Cause

Remedy

1 2

1 2

Poor engine condition. Torque converter reaction member clutch slipping.

Check and if necessary repair engine. Check and if necessary repair torque converter.

9803/3630

Issue 3*


Section F

www.WorkshopManuals.co.uk Transmission *

4-2 *


4-2


Fault Finding (continued)

* LOW CONVERTER OUT PRESSURE Possible Cause 1 2 3

Low mainline pressure. Converter internal leakage. Converter relief valve faulty.

Remedy 1 2 3

See fault heading 'Low Mainline Pressure'. Check and if necessary renew converter. Check and if necessary repair relief valve.

LOW PUMP FLOW Possible Cause

Remedy

1 2

1 2

Low oil level Blocked suction strainer.

Top up system. Clean suction strainer.

HIGH CONVERTER OUT PRESSURE Possible Cause

Remedy

1

1

Oil cooler/lines blockage.

Clean cooler, free blockage.

LOW LUBRICATION PRESSURE Possible Cause

Remedy

1 2 3 4 5

1 2 3 4 5

Low mainline pressure Oil cooler/lines blockage. Ruptured lubrication line. Converter internal leakage. Converter relief valve faulty.

OVERHEATING Possible Cause 1 2 3 4 5 6 7 8 9 10

11

See fault 'Low Mainline Pressure'. Clean cooler, free blockage. Repair line. Check and if necessary renew converter. Check and if necessary repair or renew relief valve.

Remedy

Low oil level. High oil level. Trapped or kinked hoses in cooler system. Low converter out pressure and flow rate. Oil cooler blockage. Operating in wrong gear range usage. Water system overheating. Oil aerated (foaming). Clutch piston(s) sticking on return stroke. Cored galleries on front housing pump mounting face wrong depth (indicated with an excessively low pressure and flow on the converter out cooling line). See illustration below. Leakage across pump mounting face and front case.

1 2 3 4 5 6 7

Top up system. Drain oil to correct level. Renew or repair hoses. Repair or renew the converter relief valve. Clean cooler. Select correct gears to suit working conditions. Rectify water system problems, e.g. 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.

S154080

9803/3630

Issue 2*


Section F




4-3

4-3

Fault Finding (continued) 2WD Cannot be Engaged In normal operation the 2/4 wheel drive clutch is spring loaded and therefore engaged to give 4 wheel drive. The clutch must be pressurised to give 2 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 fuses B1 and B2 is intact. Check that the 4-wheel drive external pipework is not damaged. Check that all the electrical connections are clean and secure. 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 (Minimum pressure required to disengage 2/4WD clutch is 8.6 bar; 125 lb/in2).

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

9

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 permanently energised.

8.2 Check the 2/4WD relay and select switch, replace as necessary.

8.3 2/4WD solenoid spool O-ring failed.

8.3 Renew O-ring.

8.4 Clutch shaft sealing rings leaking.

8.4 Renew clutch shaft sealing rings.

8.5 Excessive clutch shaft end float.

8.5 Rectify fault, renew parts as required, reset end float (should not exceed 0.03 mm; 0.001 in)

8.6 Wrong type clutch piston fitted.

8.6 Fit correct type clutch piston (ie, without bleed hole).

8.7 Clutch piston O-ring failed.

8.7 Replace clutch piston O-ring.

Defective 2/4WD clutch:

9

Rectify fault:

9.1 Worn pressure plate

9.1 Inspect pressure plate, renew as required.

9.2 Worn actuating sleeve.

9.2 Measure length of actuating sleeve and renew as required.

9.3 Incorrect clutch pack end float.

9.3 Measure clutch pack end float. Correct as required.

4WD Cannot be Engaged No pressure is required to engage 4WD (spring loaded). Check that the drive train is intact (ie propshaft and axle). Also check that the solenoid spool is not sticking (in the 2WD position). Finally check the 2/4 wheel drive switch and relays. * No 4WD Check that the 4 wheel drive gear has been fitted the correct way round (see PS750 Layshaft - Assembly). * Noise from 4WD when Braking Caused by clutch pack taking up speed differential - This is normal. 9803/3630

Issue 3*


Section F


4-4

*


4-4


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 Checking Transmission Oil Level Routine Maintenance -

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. Insufficient lubrication.

Fit new bearings. Carry out flushing procedure. Refill with JCB Special Transmission Fluid.

Spring retainer/oil baffle plate fitted in wrong order.

Reassemble layshaft (see PS750, Lay Shaft Assembly).

4

*5

Badly worn/noisy bearings.

1st/2nd gear slipping or noise.

9803/3630

Issue 2*


Section F




5-1

5-1

A

A296900

F

C

G B E

D

A297010

9803/3630

Issue 1


Section F


5-2


5-2

Removal and Replacement Removal 1

Due to the configuration of the engine and transmission mounting system the powershift gearbox should be removed from the machine, together with the engine, bevel gearbox, torque converter and hydraulic pump as a complete assembly. See Engine and Transmission Removal and Replacement, Section K.

* When assembling offer the gearbox square to the torque converter housing. 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. DO NOT use housing bolts or any other device to pull the assemblies together.

2

Support the engine and transmission assembly on a suitable frame, as shown at A and remove the lifting beam (see Section K).

Remember to refit any cable tie locaters retained by the bolts G. Torque Settings

Make sure that the engine will be safely supported when the transmission components are removed. 3

Label and disconnect the external oil hoses and pipes, typically as follows: B, C D E F

-

* Item *G *H J

Nm 56 18 56

kgf m 5.7 1.8 5.7

lbf ft 41 13 41

Oil cooler hoses. Bevel gearbox drain pipe. 2/4 wheel drive clutch feed pipe (if fitted). Remote oil filter pipes (if fitted).

4

Support the gearbox with suitable lifting gear and undo the gearbox to torque converter housing bolts G.

*5

Carefully withdraw the gearbox from the torque converter, keeping the assemblies square to each other.

Replacement Replacement is the reversal of the removal procedure. * Note: Before replacing the powershift check to see if pressure test points H and J are fitted at the clutch pressure test points (see Pressure and Flow Testing for test point identification). * It is advisable to fit test points before replacing the powershift due to restricted access, particularly on 530 machines. * Fit test points as follows: *1

Thoroughly clean the area around the plug to prevent dirt and water ingress before removing the plug.

*2

Degrease all threads. Use JCB Threadlocker and Sealer and tighten the test points to the torque figures shown below.

*3

Ensure the protective cap is fitted to the test point after use.

HJ

* Test points required as follows: * H J

Part No. 892/00964 892/00965

(1/8 BSP) (3/8 BSP)

Qty 5 1 320380A

9803/3630

Issue 2*


Section F


5-3 * Summary 1


5-3

of Changes - 4 Speed

Reverser Clutch Pack Shaft 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 with reverser shaft cover plate.

Powershift with reverser shaft sealing plug & PS 750.

S217380

2

A311480 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 procedure for the PS750 clutch packs differ from the PS700 but have been kept together in the Service Manual for simplicity purposes, make sure you use the correct procedure.

9803/3630

Issue 3*


9803/3630


12

21

24

12

12

15

21 12

23

9

1

1

16

20

13

1

1

12

22

A264570

11

14

9 85

20 - 24 25 - 28 12 400

7 8 9 10 11

kgf m

Select shims to give mainshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.). Select shims to give layshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

14

15

www.WorkshopManuals.co.uk Transmission .....continued

Select shims to give input shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

13

40

1.2

2.5 - 2.8

2.0 - 2.4

8.6

1.0

0.6 - 0.8

10.4

20.7

0.8 - 1.0

5.7

Notes Bearings to be lightly oiled before setting and must be rotated whilst being set.

296

8.8

18 - 20

14.8 - 17.7

63

7.4

4 - 5.9

75

150

5.9 - 7.4

41

lbf ft

Item 12

Assembly Notes

10

6

5-8

102

5

4

8 - 10

2 203

56

1 3

Nm

Item

Torque Settings

Torque Figures and Assembly Notes

Sheet 1 of 3 5-4

19

18

12

1

PS700 (4 Speed) Section Views and Torque Figures

Section F www.maskinisten.net Section F


Issue 3

9803/3630


PART SECTION D-D

9

17

17A

10

1

1

1

9

1

6

4

9

9

1

1

A264581

1

SECTION B-B (SEE SHEET 1)

7

Select shims to give reverser shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

17

Measure end float of pressure plate. Free movement on plates to be :

21

www.WorkshopManuals.co.uk Transmission Fit shim plates, between pressure plate and circlip.

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).

Assemble with tapped extraction holes facing out.

The procedure for tightening the stake nut varies depending on whether a solid spacer or collapsible spacer is fitted. See Assembly Procedure for details.

19

20

Pack cavity between seal lips with grease before assembly.

18

On later transmissions the reverser cover 17A is replaced by an inspection plug and requires a different procedure, see Summary of Changes.

Select shims to give 4WD output shaft end play of 0.03 mm (0.001 in) maximum.

16

17A

Notes

Item

Assembly Notes (continued)

Sheet 2 of 3 5-5

5

PART VIEW ON ARROW H

8

1

PS700 (4 Speed) Section Views and Torque Figures (continued)



Issue 4*

9

PART VIEW ON ARROW G (SEE SHEET 1)

1

1

9

9

PART SECTI ON A-A (SEE SHEET 1)

3

4

Pack bearing with grease before assembly. Assemble at three positions in oil ways in front of case flange. 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.

22

23

24


9803/3630

Purchased from www.WorkshopManuals.co.uk *A264591

4

Notes

Item


Sheet 3 of 3 5-6

PART VIEW ON ARROW F (SEE SHEET 1)

1

1

PS700 (4 Speed) Section Views and Torque Figures (continued)


5-6

Issue 3*

9803/3630


12

12

21

19

12

15 9

12

1

12

16

11

0.8 - 1.0

40

1.2

2.5 - 2.8

2.0 - 2.4

8.6

1.0

0.6 - 0.8

10.4

20.7

.....continued

Select shims to give layshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

Select shims to give mainshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

14

15

Select shims to give input shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).


A324810 449/00002

kgf m 5.7

Notes Bearings to be lightly oiled before setting and must be rotated whilst being set.

296

8.8

18.4 - 20

14.8 - 17.7

63

7.4

4 - 5.9

75

150

5.9 - 7.4

41

lbf ft

13

Item 12

Assembly Notes

400

20 14

25 - 28

9

12

20 - 24

8 10

85

5-8

5 10

102

4

7

203

3

6

8 - 10

2

11

12

1

13

12

9

56

1

12

1

1

Nm

Item

Torque Settings


Sheet 1 of 3 5-7

18

12

1




Issue 2

9803/3630


PART SECTION D-D

17

4

10

9

1 1 1

9

6

4

*A324822 449/00002

9

1

1

1

9

7

SECTION B-B (SEE SHEET 1) SHOWN WITH PARKBRAKE CALIPER REMOVED FOR CLARITY

Select shims to give reverser shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.). Pack cavity between seal lips with grease before assembly.

17

18

21

20

www.WorkshopManuals.co.uk Transmission Powershift Transmission .....continued

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.

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.

Assemble with tapped extraction holes facing out.

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.

Select shims to give 4WD output shaft to give 4WD output shaft end play of 0.03 mm (0.001 in) maximum.

16

19

Notes

Item


Sheet 2 of 3 5-8

12

PART VIEW ON ARROW H

5

1

8

* PS750 (4 Speed) Section Views and Torque Figures (continued)


5-8

Issue 3*

9

9

9803/3630


1

9

9

1

PART SECTION A-A (SEE SHEET 1)

1

3

4

A324831 449/00002

4

Pack bearings with grease before assembly. 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.

24

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.

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).

Notes Measure end float of pressure plate. Free movement on plates to be :

23

Item 22


Sheet 3 of 3 5-9

PART VIEW ON ARROW F (SEE SHEET 1)

1

1

PART VIEW ON ARROW G (SEE SHEET 1)

* PS750 (4 Speed) Section Views and Torque Figures (continued)

Section F

www.WorkshopManuals.co.uk Transmission www.maskinisten.net Section F


Issue 3*

14

23

14

B

17

8

A

A

1

16

9803/3630

Purchased from www.WorkshopManuals.co.uk A362480

2

22 1

15

8

296

292

221

122

8.8

8.8

18 - 20

14.8 - 17.7

7.4

4 - 5.9

75

150

5.9 - 7.4

41

lbf ft

kgf m

40

40

30.6

16.9

1.2

1.2

2.5 - 2.8

2.0 - 2.4

1.0

0.6 - 0.8

10.4

20.7

0.8 - 1.0

5.7

Select shims to give input shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.). Select shims to give mainshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.). .....continued

16

Bearings to be lightly oiled before setting and must be rotated whilst being set. 15

Item 14

Assembly Notes

††Stake nut sleeve to be split axially using square ended staking tool.

†Ensure grub screw does not protrude above mounting face.

400

396 13 ††

300

12

9A

12

12

9†

11††

25 - 28

8

166

20 - 24

7

10

10

6

102

4 5-8

203

3 5

8 - 10

2

56

1


A264570

13

24

12

18

Nm

Item

Torque Settings


Sheet 1 of 3

5 - 10

20

11

B



Powershift Transmission 5 - 10

Issue 1

0 98 02 7/ 81

S ON SI IS o SM L N AN RIA TR SE

9803/3630


8

7

5

1

H

4

D

D

1

SECTION B-B (SEE SHEET 1) SHOWN WITH BRAKE CALIPER REMOVED FOR CLARITY

PART SECTION ON D-D

19

4

9A

E

8

6

E

5

10

A362490

C

*A362491

7

8

7

1

1

8

C

Sheet 2 of 3

24

23

22

21

20

Add grease before assembly of PPA washer.

Fit spacer to give bearing setting between 0.03mm (0.001in) end play and 0.05mm (0.002in) preload.

Assemble with tapped extraction holes outboard.

Assemble at three positions on oilways in front case flange.

Pack cavity between seal lips with grease before assembly.

Select shims to give reverser shaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

Select shims to give 4WD output shaft and 5-Speed shaft of between 0.03 mm pre-load and 0.03mm (0.001in) end play

18

19

Select shims to give layshaft end play of 0.03 to 0.08mm (0.001 to 0.003 in.).

17

Item


5 - 11

PART VIEW ON ‘H’

IO RAT

1

7


Section F



5 - 11

Issue 2*

8

PART VIEW ON ARROW ‘F’

1

1

9

1

1

1

20

4

9803/3630


*A362501 A362500

3

SECTION A-A (SEE SHEET 1

4


SECTION E-E (SEE SHEET 2)

F

21

8

Sheet 3 of 3 5 - 12

G

1

8

1

PART VIEW ON ARROW ‘G’



5 - 12

Issue 2*

Section F



6-1

Powershift - 4 Speed (With Reverser Shaft Cover Plate)

6-1

Dismantling 3 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.

Note: Some machines have a remotely located filter. 3

Remove the mainline pressure test adaptor. If the speed sensor A (when fitted) is to be removed, make sure that the spacer (if fitted) and ‘O’ ring beneath are retrieved.

2

A

1

A297050 S217450

4

Unscrew bolts and withdraw the torque converter pump assembly.

5

Remove and discard the pump sealing ring.

6

Separate pump components.

7

Remove and discard oil seal from pump housing.

5 4

If the reason for dismantling the transmission is pump renewal only, the housing B must be removed, together with the pump. When assembling, fit the pump, and then housing B.

B 7 Before removing solenoids remove the electronic control unit (when fitted), see Section C, Contents. 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 forward high/low clutch solenoid valve.

S217430

10

9

8

See solenoid valve dismantling and assembly procedure.

S296930

9803/3630

Issue 4


Section F


6-2

*Powershift - 4 Speed (With Reverser Shaft Cover Plate)

6-2

Dismantling (continued) 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.

16

Unscrew plug and withdraw pressure maintenance valve spool and spring.


16

11

14

12

13 S217170

17

Unscrew 11 bolts and remove the 4 wheel drive unit with its clutch assembly. See 2/4 Wheel Drive for dismantling and assembly procedures.

17

Note: 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

9803/3630

Issue 4*


Section F



6-3


6-3


Position transmission vertically, standing on face of torque converter housing as shown.

20

CAUTION: The Powershift transmission weighs approximately 236 kg (519 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

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

23

Note the three 'O' rings (fitted next to the input and reverse clutch assemblies).

Q 24

T

V

Tilt and lift out the layshaft assembly T. See layshaft dismantling and assembly procedure.

23 Note: For reference, the clutch assemblies are identified as follows: P = Reverse Clutch T = Layshaft 25

Q = Mainshaft V = Input Clutch

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 reverse clutch P. See clutch dismantling and assembly procedure.

26

P

Slightly lift the input clutch and at the same time tilt and lift out the mainshaft Q. See mainshaft dismantling and assembly procedure.

27

Lift out the input clutch.

9803/3630

S217210

Issue 4*


Section F



6-4


6-4


Unscrew 11 bolts and remove the torque converter housing.

28

S217220

29

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.

29

Note: Due to ratio options some transmissions feature a larger diameter output gear Z. When removing the output shaft the gear may foul the gearbox housing, preventing removal. For shaft removal procedure see Output Shaft Removal - Larger Diameter Gear. 30

Prise out oil seal and discard.

31

Remove outer taper roller bearing

32

Remove spacer and retain for assembly.

30 31

Note: If spacer 32 is the collapsible type X, discard it. 33

Using a suitable puller, withdraw output shaft inner bearing.

32

X 33

Z

9803/3630

S217201

Issue 4*


Section F



6-5


6-5


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

9803/3630

Issue 4*


Section F 7-1



7-1

*Powershift

- 4 Speed (With Reverser Shaft Cover Plate)

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. End spacers have extraction holes to assist removal.

4

S217230

3 S217240

Fit the torque converter housing. Fit bolts and torque to 56 Nm (42 lbf ft).

Note: The torque converter 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.

4 S217220

9803/3630

Issue 5*


Section F


7-2


7-2


*

Assembly (continued) 5

Lightly oil output shaft inner bearing 5 and cup and fit to the output shaft.

7 The transmission should be rebuilt with a solid spacer K, 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.

6

See Service Tools, Section 1 for Setting Tool Kit, part number and details of spacers. a

Fit the solid spacer K (13.70 mm thick, part number 921/52620) over the output shaft and assemble into the casing.

b Lightly oil output shaft outer bearing 6 and cup and fit to the output shaft, do not fit oil seal 7 at this stage.

13.70

K

K 5

6

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: The bearing cups are pushed fully into the casing.

B

The correct bearings are fitted.

D A

The solid spacer K 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

9803/3630

Issue 4*


Section F



7-3

* Powershift


7-3


a

Fit dial test indicator (DTI) E.

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 K, subtract the end float obtained at step b from the solid spacer (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

n s F

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.

S265910

d Remove nut B, sleeve A, outer bearing G and fit correct size spacer K. Take care to avoid damaging the outer bearing.

B

Note: In order to remove bearing G the output shaft H must be removed. Due to ratio options some transmissions feature a larger diameter output gear. When removing the output shaft the gear may foul the transmission housing, preventing removal. For shaft removal procedure see Output Shaft Removal - Larger Diameter Gear.

f

8

a

K

A311530

e

A G

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.

B A

H

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.

Remove nut B and sleeve A. Fit new oil seal 7 (grease between seal lips before fitting). Assemble brake disc/flange J (the disc/flange may be a tight fit) using the alignment marks made during dismantling.

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. b Fit NEW retaining nut and washer 8 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.

S265900

*

8

J

7

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

Finally stake nut 8 into the slot in the shaft.

9803/3630

A273410

Issue 4*


Section F



7-4


7-4

*


Position transmission vertically, standing on face of torque converter 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

9803/3630

Issue 4*


Section F



7-5

* Powershift


7-5


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 Lock and Seal 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

9803/3630

Issue 4*


Section F



7-6

*Powershift


7-6


21

Position the transmission horizontally. Unscrew bolts and remove the torque converter 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

9803/3630

Issue 4*


Section F

www.WorkshopManuals.co.uk Transmission * Powershift


7-7



7-7

*

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

9803/3630

Issue 4*


Section F



7-8

* Powershift


7-8


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

9803/3630

Issue 4*


Section F


7-9

* Powershift


7-9



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

Fit a new pump sealing ring.

36

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.

37

37 35 36

Make sure all bearings have been lubricated with JCB HP Grease. Apply JCB Multi-gasket to mating face of torque converter housing. Fit the torque converter housing, apply JCB Threadlocker and Sealer to bolts and torque to 56 Nm (42 lbf ft).

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

9803/3630

Issue 4*


Section F



7 - 10

*


7 - 10


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).

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).

43 *

44

45

S217170

46

Note: The mounting holes will only align when the solenoid valve has been positioned correctly on the adaptor block. Fit the electronic control unit (when applicable). The ECU can be damaged if it is incorrectly fitted. See Section C, Contents.

9803/3630

S296930

Issue 4*


Section F



7 - 11


7 - 11

Assembly (continued)

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

C

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.

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

49

Smear seal of new filter with oil and install hand tight only.

50

Fit the drain plug with a new sealing washer - torque tighten to 203 Nm (150 lbf ft).

51

Refit the mainline pressure test adaptor with a new sealing washer.

51

49 50

S217450

9803/3630

Issue 2*



Section F


*Powershift - 4 Speed (With Reverser Shaft Sealing Plug & PS750)

8-1

8-1

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

28

9804/3630

A311910

Issue 4*


Section F

www.WorkshopManuals.co.uk Transmission Powershift - 4 Speed (With Reverser Shaft Sealing Plug & PS750)

8-2


8-2

Component List 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

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.

9803/3630

Issue 4


Section F



Powershift - 4 Speed (With Reverser Shaft Sealing Plug & PS750)

8-3

8-3

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

! CAUTION When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer. 2-3-4-1

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

If the speed sensor 7 is to be removed, remove two capscrews 7A and 7B, the spacer 7C and speed sensor guard 7D, if fitted.

7B

Remove the capscrew holding the speed sensor 7 and its spacer 7E and ‘O’ ring 7F . Retain the spacer for assembly.

*

S217452

7C

7A

7D 385900

7

7E

7F

8

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.

9

Similarly remove the mainshaft/ layshaft clutch solenoid valve 11.

10 Similarly remove the forward high/low clutch solenoid valve 12.

A312081

10

13

11

12

A310580

9

When the solenoid valves are removed, discard the four surface mounted ‘O’ rings 13 from the valve body. Refer to Solenoid Valve, Dismantling and Assembly if further work is necessary on any of the solenoid valves.

8

9803/3630

Issue 4*


Section F




8-4

8-4

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

9803/3630

23

Issue 2*


Section F



*Powershift

- 4 Speed (With Reverser Shaft Sealing Plug & PS750)

8-5

8-5

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 Wheel Drive Unit - Dismantling and Assembly.

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

9803/3630

Issue 2*


Section F



*Powershift


8-6

8-6

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). 29 Tilt and lift out the layshaft assembly T. Note: For reference, the clutch assemblies are identified as follows: P = Reverser Clutch T = Layshaft

T 37

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.

P

32 Lift out the input clutch V.

X

S217210

Note: Retrieve shims 38 from casing for re-use, see complete assembly illustration at the begining 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.

9803/3630

Issue 2*


Section F



*Powershift


8-7

8-7

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. 35 Prise out oil seal 45 and discard.

43

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.

Y 47 44

X

48

S217201

9803/3630

Issue 2*


Section F

www.WorkshopManuals.co.uk Transmission *Powershift - 4 Speed (With Reverser Shaft Sealing Plug & PS750)

9-1


9-1

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.


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

3

Lightly oil output shaft inner bearing 48 and cup and fit to output shaft 44.

45 46

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. See Service Tools, Section 1 for Setting Tool Kit, part number and details of spacers. a

36

Fit the solid spacer 47 (13.70 mm thick, part number 921/52620) over output shaft 44 and assemble into casing 36.

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.

47

13.70

47

44 48

9803/3630

Issue 5*


Section F




9-2

9-2

Assembly (cont’d) 4


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


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.


13.70 0.41 13.29 0.12 13.17


13.15

F S265910


B

d Remove nut B, sleeve A, outer bearing and fit correct size spacer 47. Take care to avoid damaging the outer bearing.

f


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

9803/3630

Issue 4*


Section F




9-3

9-3


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


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

9803/3630

Issue 2*


Section F




9-4

9-4


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

9803/3630

Issue 2*


Section F




9-5

9-5

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

C

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).

9803/3630

A

A311270

Issue 2*


Section F


9-6



9-6

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. 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 Polytetrafluroethane (P.T.F.E.) 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.

52

9803/3630

S217300

Issue 2*


Section F




9-7

9-7

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).

31

30

32

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). 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.

33


A217341

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

Select adapter 8 from the kit and screw into the tapped hole in the layshaft.

A

B


f

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.

11

5 8 2

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

3

A310530

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.)

9803/3630

Issue 2*


Section F


9-8



9-8

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

9803/3630

Issue 2*


Section F




9-9

9-9

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 mainhaft 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.

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.

9803/3630

Issue 2*


Section F




9 - 10

9 - 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. 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, Dismantling and Assembly.

26

9803/3630

S311550

Issue 2*


Section F


9 - 11



9 - 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 7 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 8

7

A 10

9 40

31 Assemble pump 15 (if dismantled). Install pump taking care to align mounting holes. Apply JCB Threadlocker and Sealer to bolts 39 and using new sealing washers, tighten to 25 Nm (18 lbf ft). Use a new pump housing seal 17. 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 17 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

9803/3630

Issue 2*


Section F




9 - 12

9 - 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 the new spring and plug combination shown below:

6.0 49.9

A311520

24

S217171

31152

Note: If the plug and spring fitted differ from the above measurements, having been superseded, fit a new plug and spring as above. 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).

A

CAUTION: Overtightening the retaining nut will cause valve failure.

122mm

Note: Because of porting differences the Powershift and Syncro Shuttle 4WD spools are not interchangeable. 65m

9803/3630

A311540

Issue 2*


Section F



Powershift - 4 Speed (With Reverser Shaft Sealing Plug & PS750)

9 -13

9 - 13

Assembly (cont’d)

B

37 Fit the 4WD assembly oil feed pipe 25 (support bracket not shown).

C

Note that 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 56Nm (42lbf 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.

9

24

9803/3630

Issue 2


Section F

www.WorkshopManuals.co.uk Transmission Powershift - 4 Speed (With Reverser Shaft Sealing Plug & PS750)

9 -14


9 - 14


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. 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 lock nut 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 7 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

A

C 7

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. * 50 Refit speed sensor guard 7D, if removed during dismantling, securing with spacer 7C and capscrews 7B and 7A.

A297050

7B

7A

7C

7D 385900

9803/3630

Issue 3*




www.maskinisten.net

Section F



10 - 1

Powershift PS750, 5 Speed

10 - 1 73 72

9 11

36

71

13

12

10

7 8 23

56

22

24

42

21

25 20

18

55

43 45

19

47

46

74 39

35 31

34 33

30 32

41

5

50 51

62 77 17

63 69

29 38 P

15

6 16

57

65

61 54

37 57 57

40

64

14 38

49

53

57 27

V Q

49

38 66 57

N 68

52

67 38 4

48 44 57 T

57

26

70

1 49

3

28

2

9803/3630

A362611

Issue 4*


Section F

www.WorkshopManuals.co.uk Transmission Powershift PS750, 5 Speed

10 - 2


10 - 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

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’ Rings 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

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

Adapter Block Gasket Brake Mounting Plate Taper Roller Bearing not used not used not used Thrust Washer Drive Gear - 5th Speed Bearing Transfer Gear Bolt Circlip Shim Bearing O ring Bearing 5th Speed Solenoid Control Valve Solenoid Coil Nut Oil Seal not used not used Sealing Ring

N P Q T V

5th Speed Clutch Assembly 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.

9803/3630

Issue 4


Section F



10 - 3


10 - 3

Dismantling 1

Make sure all the oil has been drained from the casing by removing drain plug 4. Drain the oil into a suitable container.

2

Remove and discard the oil filter 5.

A

Note: Some machines have a remotely located filter. 3

Remove the mainline pressure test adapter A.

5 4

S217450

4

If the speed sensor 7 is to be removed, remove two capscrews 7A and 7B, the spacer 7C and speed sensor guard 7D, if fitted.

7B

Remove the capscrew 7H holding the speed sensor 7 and its spacer 7E and ‘O’ ring 7F . Retain the spacer for assembly.

7D

7A

7C 7

7E

7F

7H 386910

5

Unscrew 13 bolts and remove the torque converter housing 40.

6

Remove and discard the oil seal 74.

74

40

A362150

9803/3630

Issue 3*


Section F



10 - 4


10 - 4

Dismantling (cont’d) 7

Unscrew the 5 speed transfer gear retaining bolt 65. If necessary hold the gear 64 with a 70 mm A/F spanner on the flats at the rear of the gear. Remove the gear 64.

64 65 114.015

8

Remove the 5 speed drive gear 62 complete with its bearing 63. Remove the sealing ring 77 and the thrust washer 61.

9

Remove and discard ‘O’ ring 69.

10

There is no need to remove the bearing unless it is to be renewed.

61 62

77

63 A362620

69

11

Unscrew bolts 14 and withdraw the transmission pump assembly 15.

12

Remove and discard the pump sealing ring 16.

13

Separate pump components. Some pump assemblies are held together with an assembly screw 1B located at the rear of the pump body. Undo the screw.

14

Remove and discard oil seal 17 from pump housing.

16 114.015

14

15

A362220

1B 17

9803/3630

Issue 2*


Section F



10 - 5


10 - 5

Dismantling (cont’d) Remove the Solenoid Control Valves 15

Remove the plastic water seals 8 to reveal cap screws 9 beneath. Undo the screws and remove the reverse high/low clutch solenoid valve 10.

16

Similarly remove the mainshaft/layshaft clutch solenoid valve 11.

17

Similarly remove the forward high/low clutch solenoid valve 12.

18

With the solenoid valves removed, discard the four surface mounted ‘O’ rings 13 from each valve body.

10

13

11

9

8

12 A310580

If the solenoids are to be dismantled, see solenoid valve dismantling and assembly procedure. S296930

19

Unscrew the nut 73 on the 5th speed clutch solenoid and remove the solenoid coil.

20

Unscrew and remove the valve spool 71.

21

Remove the 2/4WD clutch solenoid 20 in the same way as the 5th speed solenoid. Remove the 4WD oil feed pipe 25.

22

Unscrew 16 bolts 23 and remove the solenoid adapter block 24.

23

Remove and discard the solenoid adapter block gasket 55.

24

Unscrew plug 21 and withdraw pressure maintenance valve spool and spring 22.

71 73

21 22

20 23

25

55 24 25

Unscrew 11 bolts 26 and remove the 4 wheel drive unit with its clutch assembly. See 2/4 Wheel Drive for dismantling and assembly procedures.

A362250

26

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 X with tool 892/00812 and loosen the 4 wheel drive flange retaining nut/bolt prior to removing the complete 4 wheel drive assembly.

S217180

9803/3630

Issue 2*


Section F


Dismantling (cont’d)

30 31

Temporarily refit the torque converter housing using 2 fixing bolts. Position transmission vertically, standing on face of torque converter housing as shown.

32 33 34

CAUTION: The Powershift transmission weighs approximately 278 kg (631 lb) when dry. A crane must be used to manoeuvre the transmission into a vertical position. 27

10 - 6


10 - 6

26


Remove the torque converter relief valve 29 ball, spring and sealing washer.

28

Remove 4 bolts 30 and remove the layshaft end cap 31.

29

Remove the layshaft shim 33 and 'O' rings 34. Discard gasket 32.

30

Remove 20 bolts 35 and lift off rear (output) end casing 36.

36

35

Note: Make sure that internal components remain seated in the front casing. If necessary, rotate the brake disc / output shaft back and forth slightly to dislodge the internal components.

31

32

29

Note the three 'O' rings 37 (fitted next to the input and reverse clutch assemblies).

A362231

Lift out the 5th speed clutch assembly N, see 5-Speed Clutch - Dismantling and Assembly.

N

Tilt and lift out the layshaft clutch assembly T.

V

See Layshaft Clutch Dismantling and Assembly procedure. Note: For reference, the clutch assemblies are identified as follows: N = 5th Speed Clutch P = Reverse/Clutch Q = Mainshaft 33

T

37

T = Layshaft V = Input Clutch

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 reverse/ clutch P. See Clutch Dismantling and Assembly procedure.

34

Q

P

Slightly lift the input clutch and at the same time tilt and lift out the mainshaft Q.

A362240

See Mainshaft Dismantling and Assembly procedure. 35

Lift out the input clutch.

9803/3630

Issue 2*


Section F



10 - 7


10 - 7


43

Whilst holding brake disc 42 with tool 992/04800, unscrew output shaft nut. Support output shaft from beneath and lift off brake disc. Remove the output shaft 44.

42

Note: Due to ratio options some transmissions feature a larger diameter output gear Z. When removing the output shaft the gear may foul the gearbox housing, preventing removal. For shaft removal procedure see Output Shaft Removal - Larger Diameter Gear. 37

Prise out oil seal 45 and discard.

38

Remove outer taper roller bearing 46.

39

Remove spacer 40 and retain for assembly.

45 46

A

Note: If spacer 40 is the collapsible type X, discard it. 40

Using a suitable puller, withdraw output shaft inner bearing.

41

If required, the parking brake bracket A may be removed at this stage. Before removal, mark the position of the bracket relative to the casing.

40 44

X

46

A362261

Z

53 42

Remove the torque converter housing. Carefully, from inside the casing, tap out the spacer 53.

43

Remove and discard the ‘O’ rings 54 from the casing.

9803/3630

54

Issue 2*


Section F



10 - 8


10 - 8


Remove two bolts 1 and withdraw the strainer 2. 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.

1 2

9803/3630

S217230

Issue 2*


Section F


11 - 1


11 - 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.


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

If the parking brake bracket A has been removed, it must be fitted at this stage in the position as marked during Dismantling, Step 41. For mounting bolt torque figures, refer to Parking Brake - Torque Figures in Section G. When building a transmission with a solid spacer, a 1.5mm (0.50in) diameter hole must be drilled at B to enable the fitting of the tool for checking the end float. 3

Lightly oil output shaft inner bearing 48 and cup and fit to output shaft 44.

45

B

A

46 75mm

373141 82mm

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 47A may be fitted as described under Collapsible Spacer - Assembly.

A 36

See Service Tools, Section 1 for Powershift End Float Setting Tool Kit, part numbers 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.

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

47

47

44

47A

48 A362591 A36

9803/3630

Issue 4*


Section F


11 - 2 *


11 - 2



C B

Note: Check for end float while tightening nut B, if there is no end float check the following: 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.

A265901

5

a


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.


13.70 0.41 13.29 0.12 13.17


13.15

F

A265911


B

d Remove nut B, sleeve A, outer bearing and fit correct size spacer 47. Take care to avoid damaging the outer bearing.

f


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. A265901

9803/3630

Issue 4*


Section F




11 - 3

11 - 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


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 four 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

A362271

9803/3630

Issue 2*


Section F




11 - 4

11 - 4


Measure the end float of the input shaft using the Powershift End Float Checking Kit, see Service Tools, Section 1.

11

A 3

a

If it has not already been done, insert an M10 bolt into the recessed hole in the base plate 2 and mount pillar 15. Tighten the bolt ensuring that the slot in the pillar faces the input shaft. Mount the base plate onto the transmission casing.

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 15. Set the wrench to 35 Nm (26 lbf ft). c

15 13

2

B 14

A311450


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


10 If the end float checking kit is not available use the following procedure: a

C

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.

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).

A362600

9803/3630

Issue 2*


Section F




11 - 5

11 - 5

Assembly (cont’d)

a

50

Remove plug 50 and sealing washer 51 from the transmission casing. Discard the washer 51.

A 3 7

b Select adapter 8 from kit and screw into the tapped hole in the reverser shaft. c

8

51

11 Measure the end float of the reverser shaft using the end float checking kit.

11

Mount base plate 2 onto the transmission casing and locate yoke 3 and wrench 11 into the adapter 8. Set the wrench to 35 Nm (26 lbf ft).

3

A311470


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 8 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).


C

Protect the reverser 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.

b 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. c

A

A362290


9803/3630

Issue 2*


Section F


11 - 6



11 - 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 9, 10, 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. When correct end float has been achieved, remove the input and reverser clutch shafts and refit piston ring seals 49 removed in step 7. Remove the bolt A (see step 12) from the reverser shaft.

38 36

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 15 to 17.

14

Refit 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.

38

A362300

54

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.

9803/3630

53 S217241

Issue 2*


Section F


11 - 7



11 - 7

Assembly (cont’d) 15 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 Polytetrafluoroethane (P.T.F.E.) Piston Ring Seal - Fitting Procedure. Also ensure that both the input clutch and mainshaft taper roller bearings have been smeared with JCB HP Grease.

A

16 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. 17 Smear the layshaft taper roller bearing with JCB HP Grease and fit the layshaft assembly T into the front case. Finally fit the 5th speed clutch assembly N. 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.

N

37

18 Using two small rods (or screwdrivers) A, align all the friction/counter plates of the mainshaft clutch.

V

19 Fit three new ‘O’ rings 37 in the front case 52. Smear the ‘O’ rings with grease to hold in position. Note: Do not apply an excessive amount of JCB Multigasket around the ‘O’ rings, too much can dislodge the ‘O’ rings. 20 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.

T

Q

P 52

9803/3630

A362240

Issue 2*


Section F




11 - 8

11 - 8

Assembly (cont’d) 21 Make sure that the layshaft bearing outer cup is fitted to the rear (output) case. Make sure all the friction/counter plates in the mainshaft clutch are aligned (see step 18). 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. Note that bolts A are longer than the other casing bolts. Apply JCB Threadlocker and Sealer to bolts and torque tighten to 56 Nm (42 lbf ft).

30

31

32

33

22 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). 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.

A

A


A362231

23 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

Select adapter 7 from the kit and screw into the tapped hole in the layshaft.

d Locate the yoke 3 and wrench 11 into the adapter 7 and pillar 6. Set the wrench to 35 Nm (26 lbf ft). e


f

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.

A

B

3

11

6 7 2

g Remove the wrench 11 and adapter 7 from the layshaft assembly.

A310530

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.)

9803/3630

Issue 2*


Section F


11 - 9



11 - 9

Assembly (cont’d) 24 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

25 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).

30 31 32 33

26 Fit a new ‘O’ rings 34 in the end cap 31. Smear the ‘O’ rings with grease to hold in position. 27 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).

34

A362231

9803/3630

Issue 1


Section F


11 - 10



11 - 10

Assembly (cont’d) 28 Measure the end float of the mainshaft using the end float checking kit. a

B

Install tool B (892/00295) over the mainshaft end bearing and spacer. Tighten bolts to 56 Nm (42 lbf ft).

b Screw adapter 4 into the tapped hole in the mainshaft. c

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.


S217351

Whilst rotating the mainshaft back and forth to seat the bearings, lift and depress wrench 11 and note the reading on the DTI.

Note: To rotate the mainshaft gain access through the 4WD cover. On 2WD transmissions use an airline and adaptor tool. f

A

4

3

Remove the wrench 11, adapter 4 and float setting tool from the mainshaft assembly.

g 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.

11 2 6

h Repeat steps 9A - 9E to recheck the input shaft end float. j

Repeat steps 11A - 11F to recheck the reverse shaft end float.

k

Remove bolt A, (see step 12) from the reverser shaft and fit plug 50 with new seal 51.

9803/3630

A311460

54 53 38

Issue 1


Section F


11 - 11



11 - 11

Assembly (cont’d) 29 If the end float checking kit is not available, use the following procedure: a

Install tool 892/00295 B over the mainshaft end bearing and spacer. Tighten bolts to 56Nm (42lbf ft).

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

B

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. 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.

9803/3630

S311430

54 53 38

Issue 1


Section F


11 - 12


11 - 12

Assembly (cont’d)

67

a

Fit the pillar 15 to the base plate 2 as shown.

c

Select adapter 16 from the kit and screw into the tapped hole in the 5th speed shaft.

66

11

30 Measure the end float of the 5th speed clutch shaft using the end float checking kit.

d Mount base plate 2 onto the gearbox casing and locate yoke 3 and wrench 11 into the adapter 16. Set the wrench to 35 Nm (26 lbf ft). e


3


A 16

B 15

f

Use a suitable bolt B and spanner to rotate the shaft back and forth to seat the bearings, and at the same time, lift and depress wrench 11 and note the reading on the DTI. 2

g Remove the wrench 11 and adapter 16 from the 5th speed shaft. A362520

h Calculate the required thickness of shims to give the correct end float which should be 0 - 0.03 mm (0 0.001 in).

67

66


Use a Dial Test Indicator and measure the end float of the 5th speed clutch assembly, which should be 0.00 - 0.03 mm (0.000 to 0.001 in).

Note: Use a suitable size bolt located in the end of the 5speed shaft to push, pull and rotate the shaft whilst measuring. 32

If the end float is incorrect remove the circlip 66.

33

Add or subtract shims 67 as required to achieve correct end float. Shims must be fitted between the bearing face and the circlip. Refit the circlip when correct shims have been selected. RECHECK end float.

S236130

34 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 bore may be sealed with either a blanking plate or by fitting 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 dismantling/assembly procedure, see Hydraulic 2/4 Wheel Drive Unit.

26

9803/3630

S311550

Issue 1


Section F


11 - 13



11 - 13

Assembly (cont’d) 35 Inspect the pump gear and casing for scoring or other signs of wear. If in doubt renew the pump. Thoroughly clean all surfaces with suitable solvent and dry before installing.

14 114.015

Make sure all bearings have been lubricated with JCB HP Grease. 36 Fit a new seal 16. Assemble pump 15 (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 a maximum of 25 Nm (18 lbf ft). Use a new pump housing seal 17. Ensure a sufficient quantity of clean new oil is added to the pump for initial start-up lubrication of the gears.

16 A362220

15 17

Note: There are two types of pump housing seal 17 depending on the pump type fitted. Ensure the correct seal is fitted:

64

Existing seal outside diameter = 68 mm (2.67 in). Alternative seal outside diameter = 68.22 mm (2.68 in).

65 37 Fit the transfer gear 64. Apply JCB HP Grease to the thread of retaining bolt 65. If necessary hold the gear with a 70mm A/F spanner on the flats at the rear of the gear. Torque tighten the bolt to 395 Nm (292 lbf ft).

114.015

38 If bearing 63 was removed, fit a new bearing to the gear using a suitable press.

62 63

39 Fit a new ‘O’ ring 69.

69

40 Fit thrust washer 61 and sealing ring 77 followed by the gear/bearing assembly over the pump drive shaft.

77

61

A362620

41 Fit a new oil seal 74 to the torque converter housing 40. 42 Make sure all bearings have been lubricated with grease. Apply JCB Multi-gasket to the mating face of the torque converter housing. Fit the torque converter housing, locating it on the dowels. Apply JCB Threadlocker and Sealer to the bolts 39 and torque to Nm (42 lbf ft).

39 74

40

39

A362150

9803/3630

Issue 1


Section F




11 - 14

11 - 14


43 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.

44 Renew ‘O’ ring and fit the 5th speed clutch valve spool 71. Install the 4WD solenoid valve body 72. Apply JCB HP Grease 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. 45 Before fitting solenoid adapter block to the casing, ensure that the M8 oilway blanking plug A is fitted. Apply JCB HP Grease to the thread and screw into position 1 mm (0.04 in) below the valve block face. 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 HP Grease to bolts and tighten to 25 - 28 Nm (18 - 20 lbf ft). 46 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.

A362280

36 21

71

72

22 20

73

Note: Fit new spring and plug combinations giving the correct operating pressures as follows:

19

High Pressure

23 28.4 62.7

A372620

55

25

24

Low and Standard Pressure

A362250

16.0 49.9

A311520

DO NOT mix springs and plugs. Ensure that springs and plugs are the correct part number 47 Renew ‘O’ ring and fit the 4WD valve spool 20. Install the 4WD solenoid valve body 19. Apply JCB HP Grease to the spool thread, fit the retaining nut and torque to 7 Nm (5 lbf ft).

A 122mm

CAUTION: Overtightening the retaining nut will cause valve failure.

65mm A311541

9803/3630

Issue 1


Section F


11 - 15



11 - 15

Assembly (cont’d)

B

48 Fit the 4WD assembly oil feed pipe 25 (support bracket not shown). Make sure that the pipe is not twisted or strained before tightening the nuts to 56Nm (42lbf ft).

C

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).

49 Renew the surface mounted ‘O’ ring seals 13 in the valve body.

D

25

50 Mount the forward high/low clutch solenoid valve 12 onto adapter block. Fit cap screws 9 and tighten to 5 Nm (4 lbf ft). 51 Repeat for the mainshaft/layshaft clutch solenoid valve 11 which may be a single coil or double coil as shown.

A

E

52 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. 53 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.

S267921

12

13

11

10

8

A310580

9

24

9803/3630

S296930

Issue 1


Section F


11 - 16



11 - 16


54 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. Note: Filter 5 is mounted in the engine compartment of 530FS Super and 540FS Super machines. 55 Fit the drain plug 4 with a new sealing washer - torque tighten to 203 Nm (150 lbf ft).

5

56 Refit the pressure switch 6 with a new sealing washer. Torque tighten the lock nut to 28 Nm (21 lbf ft).

4

57 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.

S217452

* 58 Fit the speed sensor 7, using a new ‘O’ ring 7F and spacer 7E, retained during dismantling. Secure with capscrew 7H.

7B

59 Fit speed sensor guard 7D, if appropriate, using capscrews 7A and 7B and spacer 7C.

7C

7D

7A

7 7H

7E 7F

386910

9803/3630

Issue 2*


Section F

www.WorkshopManuals.co.uk Transmission Powershift PS700

12 - 1


12 - 1

Input Clutch and Reverser Clutch Location of Components - Input Clutch

9803/3630

Issue 4


Section F


12 - 2 * Input


12 - 2

Clutch and Reverser Clutch (continued)

Location of Components - Input Clutch (continued) 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 27

DESCRIPTION

Input clutch assembly Clutch housing ‘O’ ring Piston assembly ‘O’ ring Piston liner Oil baffle Spring Spring retainer Circlip Disc spring Pressure plate (6 mm) Friction plates Counter plates Circlip Toothed shim plate Thrust washer Thrust bearing Thrust washer Plate carrier assembly housing Plate carrier assembly housing Bearing Thrust washer Bearing Seal ring Shim kit

9803/3630

Issue 4*


Section F 12 - 3



12 - 3

Input Clutch and Reverser Clutch (continued) Location of Components - Reverser Clutch

9803/3630

Issue 4*


Section F


12 - 4


12 - 4

Input Clutch and Reverser Clutch (continued) Location of Components - Reverser Clutch (continued) 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 27 28

DESCRIPTION

Reverser clutch Clutch housing ‘O’ ring Piston assembly ‘O’ ring Piston liner Oil baffle Spring Spring retainer Circlip Disc spring Pressure plate (6 mm) Friction plate Counter plate Circlip Toothed shim plate Thrust washer Thrust bearing Thrust washer Plate carrier assembly housing Plate carrier assembly housing Bearing Thrust washer Bearing Seal ring Shim kit Spacer

9803/3630

Issue 2*


Section F


12 - 5


12 - 5

Input Clutch and 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

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.

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, needle thrust bearing and thrust washers.

Note: Where transmissions are fitted with a nylon thrust washer assembly, these items should be discarded and replaced by the needle roller bearing and thrust washers during assembly. 4

3

Withdraw the gear and splined hub assembly with the needle roller bearing.

4

A264661

5

Remove thrust washers and needle roller thrust bearing (see Note at Step 3).

6

Remove the clutch friction/counter plates retaining circlip.

7

Remove outer pressure (end) plate.

Note: Later clutches are fitted with one 6 mm thick pressure plate in place of two 4 mm thick plates.

5

6 7

A217541

9803/3630

Issue 2*


Section F



Powershift PS700

12 - 6

12 - 6

Input Clutch and Reverser Clutch - Dismantling (continued) 8

9

Remove the clutch friction/counter plates. Keep them together in sets, DO NOT mix the plates with those from other clutches.

8

Remove last counter plate.

Note: In later clutches an additional counterplate is fitted beneath the pressure plate.

9

10

10

Remove disc spring assembly.

Note: The disc spring is assembled within a liner (not shown) to protect the hub support spline. S232741

11

Position clutch assembly in a press, with a cutaway tube Y compress the piston spring then remove circlip.

11

Y

Note: If no press is available, spring compressor tool 892/00916 can be used. Refit the circlip removed at step 6, and locate the feet of the tool underneath the circlip. Fit the ‘C’ plate B over the spring retaining plate, use the two bolts C to relieve spring tension and remove the circlip D. 12

12

A145000

13 13A

Lift off spring retaining plate.

Note: Assemblies with aluminium pistons have an oil plate 13A fitted. 13

A264671

Remove spring and oil baffle plate.

C

C

A

B S267310

D 259320

9803/3630

Issue 2*


Section F



Powershift PS700

12 - 7

12 - 7

Input Clutch and Reverser Clutch - Dismantling (continued) 14

Knock the clutch shaft on a piece of aluminimum (or wood) to remove the piston.

s

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 (not shown).

15

Note: The plastic type piston is shown at A. 16

Repeat steps 2 to 15 to dismantle the opposite clutch.

A A264721

9803/3630

Issue 2*


Section F



Powershift PS700

12 - 8

12 - 8

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 the housing.

X

Ensure the outer ‘O’ ring seal 1 (part no. 828/00414) is correctly seated in its groove. Check that the ball valve X is seating correctly. 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 plate 2A will also be required.

1

A A264721

2

Install the oil baffle and piston spring, make sure the spring seats in the piston.

4

3

Fit the spring retaining plate.

3

4

Position the clutch assembly in a press, with a cutaway tube Y, compress the piston spring then fit circlip.

2 2A

If a press is not available use spring compressor tool 892/00916 and fit circlip D.

A264671

Y

A145000

D S295320

9803/3630

Issue 2*


Section F



Powershift PS700

12 - 9

12 - 9

Input Clutch & Reverser Clutch - Assembly (continued) 5

Inspect the disc spring for signs of contact at X, with 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, make sure it is fitted the right way round as shown at A.

A

X

Note: The disc spring is assembled within a crimped housing (not shown) to protect the hub support spline.

S167530

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 S217550

Note 1: In later clutches an additional counter plate is fitted before fitting the pressure plate. Note 2: When assembling the friction and counterplates ensure they are located to clear the oilways in the clutch body.

7 6 5

A232742

9

Fit the pressure (end) plate. Make sure that the prongs on the pressure plate DO NOT locate in the large grooves in the housing (the ones with drilled holes).

Note: Later clutches are fitted with one 6 mm thick pressure plate in place of two 4 mm thick plates. 10

10

9

Fit the clutch friction/counter plates retaining circlip.

A217580

11

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). If necessary, fit shim between the retaining circlip and pressure (end) plate to correct end float inaccuracies.

Note: Later type shims have teeth on the outside diameter to prevent spinning during operation. Discard old type shims, use new type shims ONLY.

S217590

9803/3630

Issue 2*


Section F



Powershift PS700

12 - 10

12 - 10

Input Clutch & Reverser Clutch Assembly (continued) 12

A

Fit thrust washer C followed by needle roller thrust bearing B and thin thrust washer A.

Note: Before fitting the thrust washers and thrust bearing inspect for damage and wear. Renew as required. If the original thrust washer X was of the nylon type discard it and fit the thin steel washer A and needle roller thrust bearing B.

B

12

X C

C

Note: The thrust washer A is slightly concave and can be fitted either way round but the preferred installation is as shown at E.

A217601

E

A 13

Fit gear and splined hub assembly.

Note: Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver). 14 15

A318840

C B

15

A

Fit needle roller bearing.

14

Fit thin thrust washer A followed by needle roller thrust bearing B and thrust washer C, (see Notes at Step 12).

C X

13 A232371

16

Smear the clutch end bearing with JCB HP Grease and press the bearing onto the shaft.

17

Fit piston ring seals.

17

Note: If the piston ring seals are the polytetrafluoroethane (PTFE) type then see Polytetrafluoroethene (PTFE) Piston Ring Seals - Fitting Procedure for the correct fitting procedure. 18

16

Repeat steps 1 to 16 for the opposite clutch, make sure that the opposite clutch end taper roller bearing is packed with grease. S232720

9803/3630

Issue 1


Section F 12 - 11


9803/3630


12 - 11

Issue 1


Section F


12 - 12


12 - 12

Mainshaft - Location of Components 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

DESCRIPTION

Piston (aluminium) Piston liner Counter plates Friction plates Disc flange Spacer Bearing Seal Washer Nut - M30 Taper roller bearing Bearing Spring Spring retainer Oil baffle ring ‘O’ ring Transfer gear Circlip Ring seal Circlip ‘O’ ring Mainshaft gear Shim kit ‘O’ ring Taper roller bearing Mainshaft spacer Toothed shim plate Pressure plate - 6 mm

9803/3630

Issue 1


Section F



Powershift PS700

12 - 13

12 - 13

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 occur. 217620

3

Remove internal circlip.

4

Remove pressure (end) plate.

Note: Later clutches are fitted with one 6 mm thick pressure plate in place of two 4 mm thick plates. 5

3 4


Note: In later clutches an additional counter plate is fitted beneath the pressure plate.

5

217630

9803/3630

Issue 1


Section F



Powershift PS700

12 - 14

12 - 14

Mainshaft - Dismantling (continued) 6

Remove taper roller bearing.

7

Position clutch assembly in press, with a cutaway tube Y compress piston spring then remove circlip.

6 7

If a press is not available use compressor spring tool 892/00916 to remove circlip D. Refit circlip removed at step 3 and locate the feet of the tool underneath the circlip. Fit ‘C’ shaped plate over the spring retaining plate, use two bolts C to relieve spring tension and remove circlip D.

217640

Y

C

A145000

D

259320

8

Remove the spring retaining plate.

Note: Assemblies with aluminium pistons have an oil baffle plate 9A fittted. 9

Remove the spring and oil baffle plate.

8 9

9A

A217652

9803/3630

Issue 1


Section F


12 - 15


12 - 15

Mainshaft - Dismantling (continued) 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.

11 Note: Make sure the piston liner is secure. The liner must be a tight fit on the piston.

A

Note: The plastic type piston is shown at A.

A217671

9803/3630

Issue 1


Section F


12 - 16


12 - 16

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 the housing.

2

A

X

Ensure the outer ‘O’ ring seal 2 (part no. 828/00414) is correctly seated in its groove. Check that the ball valve X is seating properly. 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 plate 2A will also be required.

1

A217671

3

Fit the piston spring and oil baffle plate.

4


4

3

2A

A217652

9803/3630

Issue 1


Section F



Powershift PS700

12 - 17

12 - 17

Mainshaft - Assembly (continued) 5

Position the clutch assembly in a press, with a cutaway tube Y, compress the piston spring then fit circlip.

5

If a press is not available use spring compressor tool 892/00916 and fit circlip D. Fit taper roller bearing.

217641

Y

A145000

D S295320

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.

Note 1: When assembling the friction and counter plates ensure they are located to clear the oilways in the clutch body. Note 2: In later clutches an additional counter plate is fitted before fitting the pressure plate. 7

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).

8

7

6

Note 3: Later clutches are fitted with one 6 mm thick pressure plate in place of two 4 mm thick plates. 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. 8


A217631

9803/3630

Issue 1


Section F


12 - 18


12 - 18

Mainshaft - Assembly (continued) 9

Using a dial test indicator as shown, measure the end float of the pressure (end) plate, which should be 2.20 to 3.50 mm (0.086 to 0.137 in). If necessary, fit shim between the retaining circlip and pressure (end) plate to correct end float inaccuracies.


A217681 A217681

10

Using a press fit a new taper roller bearing. Fit piston ring seals.

Note: If the piston ring seals are the polytetrafluoroethane (PTFE) type then see Polytetrafluoroethene (PTFE) Piston Ring Seals - Fitting Procedure for the correct fitting procedure.

10

217620

9803/3630

Issue 1


Section F 12 - 19


9803/3630


12 - 19

Issue 1


Section F


12 - 20


12 - 20

Layshaft - Location of Components ITEM 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 33

DESCRIPTION

Piston (aluminium) Piston liner Counter plates Bolt Spring Oil baffle ring Spring retainer ‘O’ ring Circlip Bearing Ring seal Shim kit Pressure plate (inner - 4 mm) Circlip ‘O’ ring Layshaft gear Needle roller bearing Washer Thrust bearing Layshaft clutch housing ‘O’ ring Gear Washer Spacer† ‘O’ ring Toothed plate shim Gasket Friction plates Pressure plate (Outer - 6 mm) Cover

† 2 Wheel Drive machines only. 4 Wheel Drive machines have a gear instead of a spacer.

9803/3630

Issue 1


Section F


12 - 21


12 - 21

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

9803/3630

Issue 1


Section F


12 - 22


12 - 22

Layshaft - Dismantling (continued) 5

Remove the spring and baffle ring.

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.

Note: Where transmissions are fitted with a nylon thrust washer assembly, these items should be discarded and replaced by the needle roller thrust bearing and thrust washers during assembly. 10

Remove the two needle roller bearings.

11

Remove thrust washers and needle roller thrust bearing (see Note above).

9

10

11

9803/3630

Issue 1


Section F


12 - 23


12 - 23

Layshaft - Dismantling (continued) 12


13

Remove the outer pressure (end) plate.

12

14


13

14

217741

15

Remove the inner pressure (end) plate.

16

Remove the piston and discard its 'O' ring.

Note: Make sure the piston liner is secure. The liner must be a tight fit on the piston.

15

A

Note the plastic type piston as shown at A.

16

A217751

9803/3630

Issue 1


Section F


12 - 24


12 - 24

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

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).

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.


217760

9803/3630

Issue 1


Section F



Powershift PS700

12 - 25

12 - 25

Layshaft - Assembly (cont'd) 7

Fit thrust washer C followed by needle roller thrust bearing B and thin thrust washer A.

Note: Before fitting the thrust washers and thrust bearing inspect for damage and wear. Renew as required. If the original thrust washer X was of the nylon type discard it and fit the thin steel washer A and needle roller thrust bearing B.

C 10 9

B

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

Fit thin thrust washer A followed by needle roller thrust bearing B and thrust washer C (see Notes at Step 7).

C X

A

E

A 8

A B 7

C A318850

11

Fit the external circlip.

12


13

Fit two new 'O' rings to the layshaft.

13 12 11

217770

9803/3630

Issue 1


Section F



Powershift PS700

12 - 26

12 - 26

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

9803/3630

Issue 1


Section F


12 - 27


12 - 27

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. (2 wheel drive machines have a spacer 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.

Note: If the piston ring seals are the polytetrafluoroethane (PTFE) type then see Polytetrafluoroethene (PTFE) Piston Ring Seals - Fitting Procedure for the correct fitting procedure.

19

217700

9803/3630

Issue 1




www.maskinisten.net

Section F



Powershift PS750

13 - 1

13 - 1

20

21

19

8

7

8

12

9

5 4

4 6A

18 17

1

2

15

16

3 14 14

11

16 20

15

17 18 8 19

12

13 10 21 7 8 9 10 11 22

13 23 26

24 6B

24

25

*324731

9803/3630

Issue 3*


Section F



Powershift PS750

13 - 2

13 - 2

Input & Reverser Clutch (4-Speed) - Dismantling 1

Carefully remove piston ring seal 1.



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 6A.

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 6B.

* 19

Repeat steps 5 to 14.

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.

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

9

%

S259310

5 2

3

11 12 9 13 14 21 17

4 6A

1

7

8 15 16 19 18 20

9803/3630

26 25 23 24 22

*324762

6B

Issue 5*


Section F



Powershift PS750

13 - 3

13 - 3

Input & Reverser Clutch (4-Speed) - 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.

Note: Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver). * 12

Fit needle roller bearing 6A.

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 Polytetrafluoroethene (PTFE) Piston Ring Seals 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). * 18

Fit needle roller bearing 6B.

19

Fit needle roller bearing thrust washer 24 and thrust washer 25.

20

Smear the clutch end bearing with JCB HP Grease and press bearing 23 onto the shaft.

21

Fit piston ring seals 22, see Polytetrafluoroethene (PTFE) Piston Ring Seals Fitting Procedure.

9803/3630

Issue 5*




www.maskinisten.net

Section F



Powershift PS750

13 - 4

13 - 4

20

21

19

8

7

8

12

9

5 4

4 6

18 17

1

2

15

16

3 14 14

11

16 20

15

17 18 8 19

12

13 10 21 7 8 9 10 11 22

13

23 25 24 26 25

9803/3630

A362470

Issue 1


Section F



Powershift PS750

13 - 5

13 - 5

Input Clutch (5 Speed) - Dismantling 1

Carefully remove piston ring seal 1.


11


12

Remove spring 17 and oil baffle 18.

2

Remove the clutch end bearing 2 and gear 3, using a collet tool and press.

13

Knock the clutch shaft on a piece of aluminium (or wood) to remove the piston 19.

3

Remove the needle roller thrust bearing and thrust washer 4.


4

Withdraw the gear and splined hub assembly 5 with the needle roller bearing 6.

14

Remove and discard piston and shaft ‘O’ rings 20 and 21.

Remove needle roller bearing thrust washer 7 and thrust washers 8.

15

To dismantle the opposite clutch, carefully remove piston ring seals 22.

16

Loosen the clutch end bearing 23 by tapping the assembly on a piece of wood, then remove end bearing using puller.

5

6


7


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.

B

%

9

Remove disc spring assembly 14.

10


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.

9

%

S259310

9

5 3

4

6

10 11

12 13 14

17

21 25

2

23

1

22

26 24

7 8

15

16

19 18

20

9803/3630

A362460

Issue 1


Section F



Powershift PS750

13 - 6

13 - 6

Input Clutch (5 Speed) - Dismantling (cont’d) 17

Remove gear and splined hub assemby 24 using suitable equipment. Note: Because item 24 is mounted on roller bearings, rather than needle roller bearings as on other clutches, removal requires extra care. There is a risk of damage to the gear teeth if appropriate equipment is not used. Conventional gear pullers may not be adequate, due to the amount of friction involved and the narrowness of the gap between the gear and the clutch pack. We recommend using an arrangement as shown, which comprises a press 1, a stand 2 and a separator tool 3. Item 3 must be modified to cater for the narrowness of the gap between the gear and the clutch pack.

1

3

2

A362450

18

Remove bearings 25 and spacer 26.

19

Repeat steps 5 to 14.

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


4


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


9


Input Clutch (5 Speed) - Assembly Visually inspect the friction and counter plates: Counter plates - light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set. Friction plates - the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set. DO NOT mix old and new plates, if a plate is damaged/worn fit a complete new set.

9803/3630

S217590

Issue 1


Section F


13 - 7

Section F www.maskinisten.net 13 - 7

Input Clutch (5 Speed) - Assembly (cont’d) 10

Fit thrust washers 8 and needle roller bearing thrust washer 7.

11

Fit gear and splined hub assembly 5.

Note: Prior to fitting gear, align teeth of clutch plates using a thin rod (screwdriver). 12

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 10 for the opposite clutch.

Note: Gear and splined hub assembly 24 is supported by two taper roller bearings 25. The end float of the gear is controlled by spacer 26. If new components are being fitted a spacer with a different thickness may be required. 17

Inspect bearings 25 for damage or signs of wear, if in doubt renew the bearings. Smear the bearings 25 with JCB HP Grease and press one of them onto the shaft.

18

Fit the gear and splined hub assembly 24.


Fit selected spacer 26 then carefully (see Note below) press the second bearing cup 25 into position.

Note: While pressing the bearing into position, continually rotate gear 24 to check for freedom of rotation. If the gear begins to tighten up, remove the gear together with the bearing and fit a slightly thicker spacer. Check to make sure that the the bearing is not damaged before refitting. If in doubt renew both bearings. 20

Check the endfloat of gear 24, which should be 0.01mm to 0.06mm. Push down and at the same time rotate the gear. Zero the dial test indicator (DTI). Use screwdrivers to lever the gear up and at the same time rotate the gear whilst measuring the end float. If the end float is too great calculate the correct spacer thickness. Make sure that this is done correctly as each time a different spacer is fitted the gear 24 and its bearing must be removed with the risk of damage to the gear and bearing.

21

Smear bearing 23 wth JCB HP Grease and press it onto the shaft.

22

Fit piston rings 22 see (PTFE) Piston Ring Seal Fitting Procedure.

9803/3630

Issue 1


Section F



*Powershift PS750

14 - 1

14 - 1

* 12 13 14 9 15

10 11

7 2

1

1

8

3

4 6 5

A324750

13 14

2

12 8

7 5

15

1

4

3

9 10 11

9803/3630

A324780 449/11320

Issue 3*


Section F


14 - 2 * Mainshaft 1

14 - 2

- Dismantling

Carefully remove piston ring seals 1.



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


5


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


11


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

4

S259310

9803/3630

Issue 2*


Section F


14 - 3 * Mainshaft


14 - 3

- 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.


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


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


9803/3630

Issue 2*




www.maskinisten.net

Section F



Powershift PS750

15 - 1

15 - 1

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

9803/3630

A324740

Issue 3*


Section F



Powershift PS750

15 - 2

15 - 2

Layshaft - Dismantling 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 ring 19.

13

Remove the outer pressure end plate 20 and shim 21, if fitted.

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.

16

Remove the piston 25.

17

Remove and discard piston ‘O’ ring 26.

1

Carefully remove piston ring seals 1.

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.

4

Lift off the piston housing 5 complete with clutch pack.

5


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

11 13

16

9803/3630

A324770 449/10086

Issue 5*


Section F


15 - 3


15 - 3

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.

14

Note: Always check that the oil baffle plate 8 and spring retaining plate 6 are in the correct order. 15

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 and that the flatter of the two faces is outermost, i.e. will be against retaining ring 19 when this is fitted. Do not fit shim 21 at this stage.


Prior to fitting the clutch assembly, align teeth of clutch plates using a thin rod (screwdriver). Wedge the plates together by inserting two blunt tools

Note: A spring disc is not fitted in this clutch pack. *5 6

Fit the clutch friction/counter plate retaining ring 19. 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

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 retaining ring 19 and pressure end plate 20.

*

A

217780

(small rounded screwdrivers A) through the bottom holes at the side of the clutch housing, as shown. Position the clutch assembly on the layshaft splined hub.

217760

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.

10

Fit thin thrust washer 15 followed by needle roller thrust bearing 14 and thrust washer 13.

11

Fit circlip 11.

12

Fit the spring 7 and oil baffle plate 8.

13

Fit two new 'O' rings 9 and 10 to the layshaft.

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. 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.

18

Smear the taper roller bearing 2 with JCB HP Grease and press the bearing onto the shaft.

19


9803/3630

Issue 4*




www.maskinisten.net

Section F



15 - 4

Powershift PS750

15 - 4

11A 9

11

12

10 8 7 5

6

4

3

25

23 21 22 20 18

19

1 17 15

16

2

14

13

24

*235982 9803/3630

Issue 2*


Section F


15 - 5


15 - 5

5th Speed Clutch - Dismantling Item 1 2 3 4 5 6 7 8 9 10 11 * 11A 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Description Ring Seals Taper Roller Bearing Gear Retaining Bolt Transfer Gear Taper Roller Bearing Spacer Circlip Thrust Washer Gear Assembly Needle Roller Bearing Thrust Washer Thrust Bearing Thrust Washer Circlip Shim Pressure Plate Friction Plate Counter Plates Circlip Spring Retaining Plate Spring Piston Assembly Piston Liner ‘O’ Ring (Piston) ‘O’ Ring (Shaft) Oil baffle Plate

9803/3630

Issue 2*


Section F



15 - 6

Powershift PS750

15 - 6

5th Speed Clutch - Dismantling (cont’d) 1


1


2


S236330

3

Remove the transfer gear retaining bolt .

4

Remove the transfer gear.

5


6

Remove the spacer.

3

4

Note: Transfer gear (item 4) and retaining bolt (item 3) shown for reference. These items must be removed whilst the clutch assembly is located in the gearbox - to facilitate removal of the clutch.

5 6

S236340

7

Remove the gear retaining circlip.

8

Remove thrust washer.

9

Remove the gear and hub assembly.

10

Remove the needle roller bearing.

11

Remove the thrust washer (see Note).

* 11A Remove the thrust bearing. 12

7 8

9 10 12

Remove the thrust washer (see Note).

Note: Take note of the shape and positions of these two thrust washers - to assist when assembling.

11A 11 *236351 9803/3630

Issue 2*


Section F



15 - 7

Powershift PS750

15 - 7

5th Speed Clutch - Dismantling (cont’d)

13

13


14

14

Remove the clutch pack shim (if fitted).

15

Remove the pressure end plate.

16

Remove the friction plates (see Note).

17

Remove the counter plates (see Note).

15 16

17

Note: Keep the friction/counter plates together in sets, do not mix the plates with those from other clutches.

A236361

18 18

Position clutch assembly in a press to compress piston spring then remove circlip.

19

Lift off spring retaining plate.

20

Remove spring and oil baffle plate 25.

19 20 25

A236371

22 21

Knock the clutch shaft on a piece of aluminimum (or wood) to remove the piston.

21

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. 22

The piston liner should be a tight fit on the piston.

23

Remove the piston ‘O’ ring and discard.

24

Remove the shaft ‘O’ ring and discard.

23

24

Note: Where the original piston is the plastic type, it should be discarded with ‘O’ rings.

A236381

9803/3630

Issue 1


Section F



15 - 8

Powershift PS750

15 - 8

15

14 13A

16 17 18 20

13

19

21

22 25

2 4 3 5 7

6

24 9 12

11

10

8

23

1

*235982

9803/3630

Issue 2*


Section F



15 - 9

Powershift PS750

15 - 9

5th Speed Clutch - Assembly 1

Fit a new shaft 'O' ring.

2

Fit a new piston 'O' ring.

Note: Ensure the outer ‘O’ ring seal 2 is correctly seated in its groove. 3

Make sure that the liner is a tight fit on the piston.

4

Lubricate with oil and press piston fully into bore of clutch housing and ensure the ball valve X is seating correctly.

3 4

X 2 1

A236431

5

Install the piston spring and oil baffle plate 25, make sure the spring seats in the piston.

7

6


6

7

Compress spring and secure with circlip.

5 25

A236371

9803/3630

Issue 2*


Section F



15 - 10

Powershift PS750

15 - 10

5th Speed Clutch - Assembly (cont’d) *8

Firstly, fit one steel counter plate followed by one friction plate.

9

Continue fitting alternate plain steel and friction plates, finishing with a friction plate.

11 12 10 9

8

Note: When assembling the friction and counter plates ensure they are located to clear the oilways in the clutch body. 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).

11

Fit the clutch friction/counter plate retaining circlip.

12

Using a dial test indicator, as shown at A, measure the end float of the pressure end plate, which should be 0.7 to 2.0 mm (0.028 to 0.079 in.). If necessary, fit shim plate 12 between the retaining circlip and the pressure end plate to correct end float inaccuracies.

A236361

A

S236390

13

18

Fit thrust washer.

17

* 13A Fit thrust bearing. 14

Fit thrust washer.

15

Fit gear and splined hub assembly.

15


Fit needle roller bearing.

16

17

Fit thrust washer.

14

18

Fit the gear retaining circlip.

13A 13

*236351

9803/3630

Issue 2*


Section F


15 - 11


15 - 11

Powershift PS750

5th Speed Clutch - Assembly (cont’d) * 19

22

Fit the bearing spacer.

20

Smear taper roller bearing with JCB HP Grease and press bearing onto shaft.

21

Fit the transfer gear.

22

Fit the retaining bolt and torque tighten to 396 Nm (292 lbf ft). Set the shaft end float; this must only be done when the 5-speed clutch assembly is intalled in the transmission - refer to Powershift PS750, 5-Speed, Assembly.

21

20 19

S236340

23

Smear the clutch end bearing with JCB HP Grease and press the bearing onto shaft.

24

Fit piston ring seals (refer to PTFE Piston Ring Seals Fitting Procedure).

24

23

S236330

9803/3630

Issue 2*


Section F


16 - 1


16 - 1

Hydraulic 2/4 Wheel Drive Unit

9803/3630

Issue 4


Section F




16 - 2

16 - 2

Hydraulic 2/4 Wheel Drive Unit (continued) Dismantling and Assembly 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. Dismantling 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.

* Two different suppliers of the thinner plates (1.6 to 1.7mm, 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. 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 reassembling and installing in the machine. Refer to Hydraulic 2/4 Wheel Drive Unit, Pressure Testing the 2/4 WD Clutch. Assembly 1

Grease the shaft 22 then fit the piston housing 21 by pressing the shaft squarely into the housing (make sure the housing is securely supported on the centre boss).

2

Fit new O-rings 19 and 20 to piston 17, locate the piston into housing 21. Fit spring steel ring 18 ensuring that it seats firmly in its groove.

3

Place the disc spring 16 into the housing 21.

4

Position the actuating sleeve 15 onto the disc spring 16.

CAUTION: There is approximately 26700N (6000lbf) clamping force acting on the springs.

5

Install the clutch drum 14 in the housing. Fit support washer 13 and drum securing circlip 12.

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.

6

Build up the clutch pack 11, installing friction plates and counter plates alternately, starting with a counterplate and finishing with a friction plate.

7

Remove the clutch drum retaining circlip 12 and support washer 13.

7

Install shim(s) 10 and pressure plate 9.

8 8

Remove clutch drum 14 and actuating sleeve 15 .

9

Remove disc spring 16.

10

Remove the piston 17 and its spring steel ring 18.

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.

11

Remove and discard piston O-rings 19 and 20.

9

12

Remove the piston housing 21 only if necessary, the housing is a press fit on shaft 22.

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.

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.

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.

* Inspection Carry out a visual inspection of the friction and counter plates. * Counter plates - light scoring/polishing is permissible, plates that are not flat, worn or heavily marked or scored must be replaced with a new set. * Friction plates - the cross hatching should be clearly visible, plates that are not flat, have friction material damage or scoring must be replaced with a new set. Do not mix old, new and worn plates.

9803/3630

Issue 3*


Section F




16 - 3

16 - 3

Hydraulic 2/4 Wheel Drive Unit (continued)

* 12

Install the 4WD output gear 5 and its needle roller bearing 6.

* 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.

* 13

Install thrust washer 4 and bearing 3.

* 22

* 14

Fit sealing ring 2 and bearing 1.

*

See note after Step 21.

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 And Sealer at this stage.

* 15

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 0.03mm (0.001 in), make a note of the end float.

*

Note: Rotate shaft whilst measuring to fully seat bearings.

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 correct, 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 shaft end float which must not exceed 0.03 mm (0.001inch), 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 and apply JCB Threadlocker And Sealer to mounting bolts D. Torque tighten the bolts to 56 Nm (42 lbf ft).

* 28

Refit the output yoke E and tighten the new retaining nut F to 400Nm; 295 lbf ft. Stake the nut to the shaft using a square ended staking tool, as shown at N.

* 29

Complete Steps 19 to 21.

Assembly (continued)

16

*

Note: Rotate shaft whilst measuring to fully seat bearings. 17

18

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 re-check the shaft end float.

19

When the shaft end float is correct, remove the yoke and fit a new oil seal M.

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.

9803/3630

Issue 2*


Section F


16 - 4


16 - 4


* 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/in2 (9.3 bar) then re-check the clutch for assembly defects, especially the clutch pack end float (the shim may not be to the correct thickness). Re-test after checking for (and rectifying) assembly defects.

B A

S185720

9803/3630

Issue 3*


Section F



16 - 5


16 - 5

Permanent 4 Wheel Drive Unit *

N

2 4 1 7

173591

12

8

5

3

6 11 10

9

317351

9803/3630

Issue 3*


Section F


16 - 6


16 - 6

* Permanent


4 Wheel Drive Unit

* Dismantling

and Assembly

Machines with permanent 4 wheel drive feature a gear and output shaft in place of the 2/4 wheel drive clutch unit on selectable 4 wheel drive machines. The shaft is driven from the layshaft in the same way as the 2/4 wheel drive clutch assembly.

* Assembly Before commencing assembly carefully inspect components for signs of wear and/or damage. In particular inspect the oil seal interface surface on the output yoke 1 for signs of scoring. Renovate or renew as required.

* Dismantling 1

2

1

Fit bearing 9 outer cup to the main transmission casing.

Hold the output yoke 1 using tool 892/00812 and loosen retaining nut 2.

2

Fit spacer 11 (if fitted), shims 10 and then bearing outer cup 8 to housing 6.

Undo housing bolts 3 and withdraw the unit from the transmission.

3

Fit bearing inner cups 8 and 9 to shaft 5.

3

Remove retaining nut 2, washer 4 (if fitted) and yoke 1. Withdraw shaft 5 from housing 6.

4

Assemble shaft 5 to housing 6. Fit yoke 1 and nut 2. DO NOT fully tighten nut 2 at this stage.

4

Remove oil seal 7 from housing 6.

5

5

If the bearings 8 and 9 are to be renewed, remove the inner cups from shaft 5. Remove the outer cup of bearing 8 from housing 6 and retrieve any shims 10 and spacer 11 (if fitted). Remove the outer cup of bearing 9 from the main transmission housing.

Fit a new gasket between the main transmission casing and housing 6. Bolt the 4WD unit to the transmission using bolts 3.

6

Hold yoke 1 using tool 892/00812 and torque tighten nut 2, DO NOT stake the nut at this stage.

7

Measure the end float of the output shaft 5. It must not exceed 0.03 mm (0.001 in). If there is no end float make sure that the shaft rotates smoothly by hand. If there is too much end float or the shaft is difficult to turn, alter shims 10 and recheck the end float.

8

Finally remove nut 2, yoke 1 and fit new oil seal 7. Carefully, refit yoke 1, avoiding damage to seal 7. Fit a NEW stake nut 2 (with integral washer), torque tighten and then stake the nut to the shaft using a square ended staking tool as shown at N.

Note: Some housings use a circlip 12 to retain the shims 10 and spacer 11. There is no need to remove circlip 12.

* Torque Settings Item 2

Nm 400

kgf m 41

9803/3630

lbf ft 295

Issue 2*


Section F


16 - 7

*


16 - 7

*

Solenoid Valve

* Dismantling Remove the surface mounted ‘O’ rings 1. 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. Dismantle the opposite solenoid in the same sequence as described above. Inspect the spool and spool bore for signs of wear, nicks scratches etc. * Assembly Assembly is the reversal of the dismantling 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. Apply a small quantity of JCB Threadlocker and Sealer to the threads in the knurled nut 2 before fitting. * Torque Settings Item 2

Nm 10 to 15

kgf m 1 to 1.5

lbf ft 8 to 10

161590

9803/3630

Issue 2*


Section F


16 - 8 * Polytetrafluoroethene *1

Transmission


16 - 8

(PTFE) Piston Ring Seals - Fitting Procedure

Wind the PTFE piston ring seal around your finger as shown, so that the seal forms a 'coil'.

*

S157250

*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.

S157260

9803/3630

Issue 2*


Section F


16 - 9 * Collapsible

16 - 9

Spacer - Assembly

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. 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

Transmission


*

4

3 S235760

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 Removal - Larger Diameter Gear. 4

Finally stake nut into slot.

1

Z A310500

9803/3630

Issue 3*


Section F 16 - 10




16 - 10

Output Shaft Removal - Larger Diameter Gears 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:

C

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.

1

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

2

3

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.

C

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.

9803/3630

Issue 1




www.maskinisten.net

Section F



17 - 1


17 - 1

Solenoid Identification When testing individual clutch pressures (see Technical Data page), 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.

P

M2

N

G1 L1

Use the tables below to determine which solenoid electrical connectors should be removed when pressure testing individual clutches. Table 1 identifies the solenoid connectors (refer to the illustration) and Table 2 identifies which clutches are engaged when the various gears are selected. Table 1 Item L2 L1 M1 M2† G2 G1 N *P

Solenoid Description Reverse High Reverse Low Layshaft Mainshaft Forward Low Forward High 2/4 Wheel Drive (energised to give 2WD) 5th Speed (5-speed gearboxes only)

G2

M1

L2 *

S296931

† Some machines have no solenoid M2 M1 energised - Layshaft M1 de-energised - Mainshaft

Table 2 Gear Selected 1st Forward 2nd Forward 3rd Forward 4th Forward * 5th Forward 1st Reverse 2nd Reverse 3rd Reverse 4th Reverse

Clutches Engaged Forward Low & Layshaft Forward High & Layshaft Forward Low & Mainshaft Forward High & Mainshaft 5th Speed & Mainshaft (5-speed gearboxes only) Reverse Low & Layshaft Reverse High & Layshaft Reverse Low & Mainshaft Reverse High & Mainshaft

* Note: On machines fitted with 5-speed transmissions, individual clutch packs (other than 2/4 wheel drive) can be energised independently using the PC based diagnostic software. Identification and testing of individual solenoids should be carried out using the diagnostic software, see Electronic Control Unit (ECU) - Using the PC Diagnostic Tool in Section C.

9803/3630

Issue 4*


Section F


17 - 2


17 - 2 *


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.

Example Only: Gear Select

Direction Clutch

Mainshaft or Layshaft

RPM Clutch

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.

2nd 3rd 2nd 3rd

Forward High Forward Low Reverse High Reverse Low

Layshaft Mainshaft Layshaft Mainshaft

2060 1990 1985 1980

1

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.

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. See Engine Technical Data for correct figure; adjust if necessary.

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.

Note:The drive is disconnected when the parking brake is applied. To test the torque converter, electrically disconnect the parking brake L. 2

Apply parking brake and footbrake firmly. If necessary, set the machine against a fixed obstruction.

3

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.

4

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.

L

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 a 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 oil flow through the converter or torque converter 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 correct as stated with the valve fixed in the closed position, the relief valve is faulty. Remember to remove the bypass and refit the relief valve after this test.

S193440

Note: If engine speeds are higher than the stated figures check the transmission for low pump flow, clutch slippage or internal leakage. To isolate a suspect clutch, tabulate the recorded readings as shown in the example.

9803/3630

Issue 3*




www.maskinisten.net

Section F


17 - 2A


17 - 2A


Test Points A B C †D †E

†F -

A

H

-

†G †H J K

-

Mainline pressure Mainshaft clutch pressure Layshaft clutch pressure Forward high ratio clutch pressure Forward low ratio clutch pressure (not 5-speed gearbox) Forward low ratio clutch pressure (5-speed gearbox only) Reverse high ratio clutch pressure Reverse low ratio clutch pressure 2/4 wheel drive clutch pressure 5th gear clutch pressure (5-speed gearbox only)

† Note: For the purposes of pressure testing ‘Reverse’ and ‘Forward’ describe the gearbox clutch designation NOT the machine direction of travel.

G 378370 378370

K

378360 378360

E

D

C

F J B 378350

9803/3630

Issue 1


Section F


17 - 3


17 - 3


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.

1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A, mainline pressure test point.

2

2 Connect a 0-20 bar (0-300 lbf/in ) pressure gauge to test connector G forward high ratio clutch test point, see Test Points opposite.

3

Remove the layshaft clutch solenoid feed connector M, this ensures that only the forward high clutch is energised when 2nd gear forward is selected.

Trans 2-1

* Note: For clutch pressure test point identification see Test Points. 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

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.

3

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:

Note: See Solenoid Identification for identification and position of solenoid feed connectors when testing other * suspect clutches. For Powershift 750 (5-speed) gearboxes, identification and testing of individual solenoids may be carried out using the ECU diagnostic software, see Electronic Control Unit (ECU) - Using the PC Diagnostic Tool in Section C. Isolation and testing of the 5th speed clutch is only possible using the diagnostic software. 4

Make sure that both sides of all four wheels are chocked. Apply the footbrake and parking brake.

5

Start engine and run at 1000 rev/min, select 2nd gear forward. Note the pressure readings on both gauges, 2 which should not vary by more than 0.7 bar (10 lbf/in ) If the difference on the gauges is greater than 0.7 bar (10 2 lbf/in ) do the following:

Example Only Gear Ratio Select Clutch

Mainshaft or Layshaft Clutch

bar

lbf/in2

1st 2nd 3rd 4th

Layshaft Layshaft Mainshaft Mainshaft

9.65 8.62 9.65 8.62

140 125 140 125

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.

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.

A

We can now confirm the forward high clutch is leaking by completing an 'Individual Clutch Leakage Test'. Note: Repeat above test using reverse clutch ratios if necessary. 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 Test Points opposite 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.

M S296930

9803/3630

Issue 4*


Section F


17 - 4


17 - 4

F


G A

C

B

E A314181

Test Points A B C E F G

-

Mainline pressure Pump flow (remove filter and fit adapters) Converter inlet/converter relief valve pressure Lubrication pressure Converter outlet pressure Cooler flow (flowmeter in line from cooler to transmission)

9803/3630

Issue 3*


Section F


17 - 5


17 - 5

Pressure and Flow Testing Before completing any of the transmission pressure/flow tests, make sure that the oil level is correct and at normal operating temperature (not less than 50 °C). To avoid false test results perform the tests in the following order, rectifying any faults before moving to the next test. a b c d e f

Mainline Pressure Pump Flow Converter In Pressure Converter Relief (Safety) Valve Pressure Lubrication Pressure Converter Out Pressure/Oil Cooler Flow Rate

! WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately. HYD 1-1

! WARNING

Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT. Trans 1-2

! WARNING DO NOT go underneath the machine with the engine running. Switch off the engine, apply the parking brake and chock both sides of all wheels before going underneath the machine. Trans 2-1

! WARNING 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

! 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

9803/3630

Issue 3*


Section F


17 - 6


17 - 6


*

A

R

A

W X

Y

2

Z

2 2 3 1 A314420

9803/3630

Issue 2*


Section F



17 - 7


17 - 7

Pressure and Flow Testing (continued) Mainline Pressure

Pump Flow - Machines fitted with remote oil filter

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.

1

Stop the engine, tag and disconnect the remote filter hoses X and Y at the filter R. Connect flow meter (892/00229) to the hoses.

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, blocked suction strainer or possible damage to the remote filter feed or return hose and pipework.

3

Repeat step 2 and note gauge readings with engine running at 2000 rev/min.

3


4

Stop engine and remove test gauge.

4

Stop the engine, remove the flow meter and reconnect hoses X and Y at the filter. Make sure that the hoses X and Y are connected correctly.

Pump Flow - Machines with direct mount filter 1

2

Stop the engine. Clean the area around the transmission oil filter R. Remove the filter and the adapter fitted to the gearbox. a

Fit one of the three alternative pump flow test adapters in place of oil filter R (see Service Tools, Section F - Transmission in Section 1). The choice of adapter is best determined by the ease of installation and/or accessibility. Note that adapter type Z is fitted as standard on machines with a remote oil filter. Fit the chosen type as follows:

X

R

Y

Type X - install item 1 in the gearbox casing. Fit item 2 and secure with item 3. Type Y - with the component parts assembled, install and secure with banjo bolt 2 screwed into the gearbox and tightened to a torque of 56 Nm (41 lbf ft, 5.7 kgf m).

A314110

Type Z - with the component parts assembled, install and secure with fitting adapter 2 screwed into the gearbox, and tightened to a torque of 56 Nm (41 lbf ft, 5.7 kgf m). b Connect flow meter W (892/00229) to the flow and return adapters (shown with arrows). 3

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.

4


5

Stop engine and remove test adaptors. Replace the gearbox adapter removed at step 1 and refit filter.

9803/3630

Issue 1


Section F



17 - 8


17 - 8

P

B

B

Z

Y N

R S

9803/3630

Issue 1


Section F


17 - 9


17 - 9

Pressure and Flow Testing (continued) Converter In Pressure Note that the converter in pressure is affected by the transmission oil temperature, cooler circuit back pressure and torque converter relief valve operation. Before carrying out tests check the operation of the relief valve (see Converter Relief (Safety) Valve Pressure). 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point B.

2

Start the engine and run between idle and 1000 rev/min. With the transmission in neutral the pressure gauge will show Converter In Pressure which should be as shown in Technical Data page. A low reading could indicate a worn pump, a worn pump would also be evident during a pump flow test. A high pressure together with low flow could be caused by a blocked oil cooler. Low pressure could be caused by a faulty pump or internal leakage.

3

Remove pressure test gauge.

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, and 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. Note: The converter relief valve operation can easily be checked during a torque converter stall test (see Torque Converter Stall Test). 1

2

Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test point B.

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.

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 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. To temporarily bypass the relief valve (prevent the valve from opening) proceed as follows: 1

Stop the engine and undo the relief valve (shown at Z).

2

Carefully remove the spring N.

3

Obtain a suitable plug, drill and tap the centre and fit a locking bolt R as shown at Y.

4

Fit the plug assembly to the relief valve housing and hold the ball S on its seat by screwing in bolt R as shown at Y. Torque tighten the bolt to approximately 30 Nm (22 lbf ft).

Fit a load valve P into the converter out line.

! CAUTION Make sure the load valve is in the OPEN position, (the adjusting knob screwed fully OUT), before starting the following pressure test. Failure to do this could damage the pump. HYD 4-4/1

DO NOT allow the pressure to exceed 8.3 bar (120 lbf/in2) or damage to the converter seals will be caused. 3

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.

Start the engine and run between idle and 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 opening setting as specified in Technical Data page.

IMPORTANT The torque converter can be damaged when the converter relief valve is bypassed. To avoid damage proceed as follows: Before starting the engine 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 and cover/plug as shown at Z.

9803/3630

Issue 1


Section F


17 - 10


17 - 10

K C

J

A314430

9803/3630

Issue 1


Section F


17 - 11


17 - 11

Pressure and Flow Testing (continued) Lubrication Pressure Note that the lubrication pressure is affected by the torque converter relief valve operation and back pressure in the oil cooler circuit. Before carrying out tests check the operation of the relief valve (see Converter Relief (Safety) Valve Pressure). 1

Stop the engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as shown at J.

2

Start the engine and run between idle and 1000 rev/min. With the transmission in neutral the pressure gauge will indicate the Lubrication Pressure which should be as specified in Technical Data page.

3

Repeat step 2 and note gauge readings with engine running at 2000 rev/min. If the pressure is high the oil cooler may be blocked (see Converter Out Pressure/Oil Cooler Flow Rate).

4

Stop engine and remove pressure gauge.

Converter Out Pressure/Oil Cooler Flow Rate Note that the converter out pressure and oil cooler flow rate are affected by the torque converter relief valve operation. Before carrying out tests check the operation of the relief valve and then bypass the relief valve (see Converter Relief (Safety) Valve Pressure and Bypassing the Converter Relief Valve). 1

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.

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. Low pressure could be caused by a faulty pump or internal leakage.

3


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, (ball, spring and cover/plug)

9803/3630

Issue 1


Section F



17 - 12


17 - 12

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. Note that the filter is remotely mounted on some machines.

5

Drain the oil from the bevel gearbox. Remove plug G. After draining replace the plug.

6

275150

Fill the transmission with fresh JCB Special Transmission Fluid. Check the oil level. See Transmission, Checking the Oil Level, Section 3 and ensure that the procedure is strictly adhered to.

IMPORTANT When filling the transmission with oil it should be noted that the bevel gearbox housing will NOT be filled with oil until the engine is started. For this reason the powershift gearbox must be filled to the ‘dry’ capacity if the bevel gearbox has been removed or the oil drained. See Lubricants and Capacities (Section 3) for the correct quantity of oil. 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.

A D

B

A297130

DO NOT stall the converter for longer than 10 seconds or the transmission fluid will overheat. 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 (see Transmission, Checking the Oil Level, Section 3).

G

A297010

9803/3630

Issue 1




www.maskinisten.net

Section F



17 - 13


17 - 13

A

Y

263531

E D E F

C

A297000 A297000

F

X E F

F

D E

S296940

C 9803/3630

Issue 1


Section F




17 - 14

17 - 14

Oil Cooler * To Machine Number 784534 Removal

Replacing

1

Stop the engine and remove the starter key. Allow the engine to cool.

Replacing is the reversal of the removal procedure.

2

Access to the transmission oil cooler is made easier if the engine pod base is removed - see Engine and Transmission - Removal and Replacement, Prepare the Machine, Section K.

1

Refill the transmission with JCB Special Transmission Fluid.

2

Refill the engine cooling system.

3

Check the transmission and engine coolant levels - see Routine Maintenance.

4

Operate the machine, stop the engine and check for water/oil leaks at the cooler hose connections.

Note: The transmission oil cooler may be located as shown at X or Y dependent on the machine. 3

Carefully loosen the cap A. Let any pressure escape. Remove the cap.

4

Disconnect the bottom hose C and drain the engine coolant. Be aware that the coolant may be hot.

IMPORTANT

5

Disconnect the electrical oil temperature sensor D.

6

Disconnect the oil feed and return hoses E. Be aware that the oil may be hot.

7

Undo the water hose clips and retaining clips F. Withdraw the cooler.

If a faulty oil cooler has been renewed, the transmission may be contaminated with water. Carry out the flushing procedure - see Flushing the Transmission Oil. After 50 - 100 operating hours drain the transmission fluid and check for signs of water contamination. There should be no contamination. Refill the transmission with fresh JCB Special Transmission Fluid and renew the oil filter. Check the oil level, see Routine Maintenance.

Testing The liquid/liquid cooler is a possible source of water contamination and should be tested for possible failure as follows: 1

Drain any remaining oil/water from the cooler.

2

Fit a blanking plug to the outlet of the cooler.

3

Connect an air supply to the transmission oil inlet.

4

Submerge the cooler in a tank of water and apply air pressure to test for leakage. If bubbles are visible there is a breakdown between the water and hydraulic circuits and the cooler must be renewed. Note: Air test pressure must not exceed 6 bar (90 lbf/in2).

5

If the cooler is not damaged, it should be cleaned and dried ready for reassembly to the machine.

9803/3630

Issue 2*


Section F


17 - 15


17 - 15


A

263531

D D E F

E

B

n C 391260

9803/3630

Issue 1


Section F




17 - 16

17 - 16

Oil Cooler From Machine Number 784535 Removal

Replacing

1

Stop the engine and remove the starter key. Allow the engine to cool.

Replacing is the reversal of the removal procedure.

2

Access to the transmission oil cooler is made easier if the engine pod base is removed - see Engine and Transmission - Removal and Replacement, Prepare the Machine, Section K.

3

Carefully loosen the cap A. Let any pressure escape. Remove the cap.

4

Disconnect the bottom hose B and drain the engine coolant. Be aware that the coolant may be hot.

5

Disconnect the electrical oil temperature sensor C.

6

Disconnect the oil feed and return hoses D. Be aware that the oil may be hot.

7

Undo the water hose clips and retaining clips E. Withdraw the cooler F.

1

Refill the transmission with JCB Special Transmission Fluid.

2

Refill the engine cooling system.

3

Check the transmission and engine coolant levels - see Routine Maintenance.

4

Operate the machine, stop the engine and check for water/oil leaks at the cooler hose connections.

IMPORTANT

Testing

If a faulty oil cooler has been renewed, the transmission may be contaminated with water. Carry out the flushing procedure - see Flushing the Transmission Oil. After 50 - 100 operating hours drain the transmission fluid and check for signs of water contamination. There should be no contamination. Refill the transmission with fresh JCB Special Transmission Fluid and renew the oil filter. Check the oil level, see Routine Maintenance.

The liquid/liquid cooler is a possible source of water contamination and should be tested for possible failure as follows: 1

Drain any remaining oil/water from the cooler.

2

Fit a blanking plug to the outlet of the cooler.

3

Connect an air supply to the transmission oil inlet.

4

Submerge the cooler in a tank of water and apply air pressure to test for leakage. If bubbles are visible there is a breakdown between the water and hydraulic circuits and the cooler must be renewed. Note: Air test pressure must not exceed 6 bar (90 lbf/in2).

5

If the cooler is not damaged, it should be cleaned and dried ready for reassembly to the machine.

9803/3630

Issue 1


Section F



18 - 1

Torque Converter

18 - 1

Removal

Replacement

1

Replacement is the reversal of the removal procedure.

2

Due to the configuration of the engine and transmission mounting system, it is advisable to remove the engine and transmission as a complete assembly. See Engine and Transmission - Removal and Replacement, Section K. Remove the powershift gearbox - see Powershift Transmission, Removal and Replacement.

3

Prise out the access panel A from the bevel gearbox torque converter housing.

4

Rotate the engine so as to gain access to one of four torque converter retaining bolts B.

5

Support the torque converter, undo and remove the four bolts B. Withdraw the torque converter.

When replacing: 1

Make sure that the drive plate C and torque converter mating faces are perfectly clean.

2

Should the drive plate C have been removed make sure that the mating faces are clean and free from burrs, before locating over the spigot on the drive flange. Fit the bolts E with JCB Threadlocker And Sealer.

3

Make sure that there are no burrs on the torque converter spigot D or to any of the mating faces adjacent to the drive plate C.

4

Locate the torque converter spigot D on the recess in the bevel box output shaft.

5

Set up a dial test indicator (DTI) as shown. Rotate the torque converter and measure the run out of the drive shaft. The run out must not exceed 0.38 mm (0.015 in).

Torque Settings Item B E

Nm 46 28

Kgf m 4.7 2.8

lbf ft 34 21

C

E D

B A 9803/3630

A296991

Issue 2


Section F 19 - 1

www.WorkshopManuals.co.uk Transmission Bevel Gearbox

19 - 1

Removal

Replacement

1

Replacement is the reversal of removal.

2

Due to the configuration of the engine and transmission mounting system the bevel gearbox should be removed from the machine, together with the engine powershift gearbox, torque converter and hydraulic pump. See Engine and Transmission - Removal and Replacement, Section K. Remove the powershift gearbox, see Powershift Transmission - Removal and Replacement.

3

Remove the torque converter, see Torque Converter Removal and Replacement.

*4

Remove the hydraulic pump, see Triple Pump, Removal and Replacement, Section E.

5

Support the bevel gearbox with suitable lifting equipment and undo the flywheel housing bolts A on the engine. Withdraw the gearbox from the engine.


Make sure that the bevel gearbox input shaft splines engage with the engine flywheel correctly. Torque Settings Item

*A

Nm 56

kgfm 5.7

lbf ft 41

A

A296980

9803/3630

Issue 3*


Section F

www.WorkshopManuals.co.uk Transmission * Bevel Gear Box

20 - 1


20 - 1

*

Z Z

B

A

Z

Z

253190

9803/3630

Issue 3*


Section F



Bevel Gear Box

20 - 2

20 - 2

Oil Seal Renewal Oil seals cannot be renewed with the gearbox in-situ. Remove the gearbox from the machine (see Transmission Removal and Replacement).

Seal Removal - Bevel Gear - B 1

Remove bolts 2.

Note: If the event of oil seal failure it is essential to diagnose and rectify the cause so as to prevent a repeat failure, especially if failure has occurred at abnormally low operating hours.

2

Withdraw bevel gear assembly B. If necessary use ‘jacking’ bolts at holes Z.

Seal Removal - Pinion Drive Gear - A

3

Use reaction block 892/00915 to hold the assembly in a vice, using a 46mm socket 892/00912 remove nut 15 .

4

Remove drive flange 17, discard ‘O’ ring 20.

5

Remove and discard triple lip seal 018 and ‘O’ ring 6.

1

Remove bolts 2.

2

Withdraw pinion drive gear assembly A. If necessary use ‘jacking’ bolts at holes Z.

Note: Keep the shim set 5, and label - ‘for use with the bevel gear assembly.’

Note: Keep the shim set 5, and label - ‘for use with the pinion drive gear assembly.’

Seal Replacement - Bevel Gear - B

3

Use reaction block 892/00915 to hold the assembly in a vice, using a 55mm socket 892/00914 remove stake nut 7 and discard nut.

1

Inspect the surface finish of drive flange 17, If any wear on the seal mating surface is evident renew the drive flange. If the surface is damaged try and renovate using fine (1000 grit) emery cloth and oil, otherwise renew.

4

Remove spacer 8, discard ‘O’ ring 11.

2

5


Make sure that the seal housing and ‘O’ ring grooves are clean and undamaged.

3

Using a suitable tapered sleeve fit a new ‘O’ ring 20. Do not fit an ‘O’ ring 6 at this stage.

4

Using a suitable mandrel press in a new triple lip seal 18. Make sure that the seal is pressed square to its housing. Carefully fit drive flange 17, make sure that the outer seal lip is seated correctly as shown at C.

5

Use reaction block 892/00915 to hold the assembly in a vice, fit washer 16, nut 15 and torque tighten using a 46mm socket 892/00912. Do not stake the nut.

6

Check the rolling torque which should be 0.50 to 2.50 Nm (0.37 to 1.84 lbf ft). Excessive rolling torque indicates an incorrectly fitted seal 18.

7

Fit the gear assembly to the main housing, remember to fit shims 5. As a precaution check the backlash and gear meshing, see Assembly. Remember to finally remove the gear assembly and fit new ‘O’ ring 6.

Seal Replacement - Pinion Drive Gear - A 1

Inspect the oil seal running surface finish of spacer 8, If any wear on the outer diameter surface is evident renew the spacer. If the surface is damaged try and renovate using fine (1000 grit) emery cloth and oil, otherwise renew.

2

Make sure that the seal housing and ‘O’ ring grooves are clean and undamaged.

3

Using a suitable tapered sleeve fit a new ‘O’ ring 11. Do not fit an ‘O’ ring 6 at this stage.

4

Using a suitable mandrel press in a new triple lip seal 9. Make sure that the seal is pressed square to its housing. Carefully fit spacer 8, make sure that the outer seal lip is seated correctly as shown at C.

5

Use reaction block 892/00915 to hold the assembly in a vice, fit nut 7 and torque tighten using a 55mm socket 892/00914. Do not stake the nut at this stage.

6

Check the rolling torque of the shaft assembly which should be 0.50 to 2.50 Nm (0.37 to 1.84 lbf ft). Excessive rolling torque indicates an incorrectly fitted seal 9.

7

Stake the nut 7 using a square ended staking tool.

8

Fit the gear assembly to the main housing, remember to fit shims 5. As a precaution check the backlash and gear meshing, see Assembly. Remember to finally remove the gear assembly and fit new ‘O’ ring 6.

C

9803/3630

A310090

Issue 1


Section F



Bevel Gear Box

20 - 3

20 - 3

Z Z

B

X

Y A

Z

Z

253190

9803/3630

Issue 1


Section F


20 - 4

Bevel Gear Box


20 - 4

Dismantling Note: If the mounting bushes 24 require renewal, note the orientation relative to the housing bosses X and Y. When removing/fitting use a suitable tube to press on the outer steel ring of the bushes. Be sure to orientate new bushes correctly and press in square to the housing bosses.

6

Press out bearing cups from the housing 4. Using a suitable drift through the 2 holes in the gear 19, drift the bearing 23 from the gear.

IMPORTANT NOTE: Do not discard any components at this stage.

Pinion Drive Gear - A 1

Remove bolts 2.

2

Withdraw pinion drive gear assembly A. If necessary use ‘jacking’ bolts at holes Z.

Note: Keep the shim set 5, and label - ‘for use with the pinion drive gear assembly.’ 3

Use reaction block 892/00915 to hold the gear assembly in a vice, using a 55mm socket 892/00914 remove stake nut 7 and discard nut.

4

Remove spacer 8, discard ‘O’ ring 11 and press out pinion gear 10. Be sure to retrieve the bearings 12, 14 and spacer 13.

5


IMPORTANT NOTE: If the bearings and/or the gear assembly is to be renewed, measure and record the dimension D. Use measuring equipment with an accuracy to within 0.01 mm. 6

Press out bearing cups from the housing 3. Using a suitable drift through the 2 holes in the gear 10, drift the bearing 14 from the gear.

Bevel Gear - B 1

Remove bolts 2.

2

Withdraw bevel gear assembly B. If necessary use ‘jacking’ bolts at holes Z.

Note: Keep the shim set 5, and label - ‘for use with the bevel gear assembly.’ 3

Use reaction block 892/00915 to hold the assembly in a vice, using a 46mm socket 892/00912 remove nut 15.

4

Remove washer 16, drive flange 17, discard ‘O’ ring 20 and press out bevel gear 19. Be sure to retrieve the bearings and cages 21, 23 and spacer 22.

5


IMPORTANT NOTE: If the bearings and/or the gear assembly is to be renewed, measure and record the dimension D. Use measuring equipment with an accuracy to within 0.01 mm.

D 9803/3630

Issue 1


Section F 20 - 5

www.WorkshopManuals.co.uk Transmission Bevel Gear Box


20 - 5

Assembly Before commencing assembly carefully inspect all components for wear and/or damage. Remember to fit new oil seals, ‘O’ rings and stake nuts as a matter of course. The bevel gear 19 and the pinion drive gear 10 are a matched pair and must be renewed as a set if either are damaged or excessively worn. It is recommended that complete built-up gear/bearing assemblies are fitted in the event of gear replacement. Make sure all bearings are packed with grease before fitting and setting. Rotate bearings while setting. Check the oil ways in the bearing carriers 3, 4 and gearbox housing 1 are clean and clear. This is particularly important if bearings have failed. Note: When re-building the gearbox using replacement or original components, the rolling torques, backlash and gear meshing must be checked and adjusted as required.

Pinion Drive Gear Assembly - A Note: The taper roller bearings 12 and 14 must be preloaded 0.01 to 0.06 mm to give a rolling torque of 0.5 to 1.5 Nm. The correct pre-load is achieved by selecting the correct thickness spacer 13. 1

Press fit the outer bearing cups 12 and 14 into the housing 3.

2

Select the largest spacer 13 and assemble with the bearings 12 and 14 in a vice as shown at C. Use a suitable socket Y as a clamping spacer.

3

Tighten the vice and measure the end float on the housing 3. To select the correct size spacer 13 do a calculation as follows: Largest spacer End float example Pre-load required Spacer required

= =

8.00 mm 0.42 mm 7.58 mm 0.04 mm 7.54 mm

A

9803/3630

Issue 1


Section F


20 - 6

Assembly

5

20 - 6

continued

Pinion Drive Gear Assembly - A Continued 4


Select the nearest size spacer 13 and re-assemble in a vice as shown at C. Carefully tighten the vice checking free rotation of housing 3. If the housing becomes stiff to turn by hand stop tightening the vice and fit the next largest spacer. The rolling torque can be measured as a rolling force using a spring balance and cord wrapped around the housing 3 as shown as shown at D. Pull the spring balance until the housing rotates and note the reading, it should be 0.70 to 2 kgf (1.5 to 4.5 lbf) where ‘d’ is 75 mm. If the rolling force is too low re-assemble using the next smallest size spacer.

8

Assemble the pinion gear and bearing 14 to the housing 3. Press fit inner bearing 12 onto the pinion gear 10.

9

Use reaction block 892/00915 to hold the assembly in a vice, fit spacer 8, nut 7 and torque tighten using a 55mm socket 892/00914. Do not stake the nut at this stage.

10

Check the rolling torque which should be 0.50 to 1.5 Nm (0.37 to 1.1 lbf ft). Remove nut 7 and spacer 8.

11

Fit new ‘O’ ring 11 and triple lip seal 9. Carefully locate spacer 8 inside the seal 9. See Renewing the Pinion Oil Seal.

*

6

When the correct spacer has been selected remove the assembly from the vice and measure dimension X (shown at E). Record the measurement.

12

Use reaction block 892/00915 to hold the assembly in a vice, fit nut 7 and torque tighten using a 55mm socket 892/00914. Do not stake the nut at this stage.

7

Press the inner bearing 14 onto the pinion gear 10. Fit selected spacer 13.

13


14

Stake the nut 7 using a square ended staking tool.

3

C Y

@

$

£ S242141

A310100

D

E

d A310410

9803/3630

X

Issue 2*


Section F


20 - 7

Assembly


20 - 7

continued

Bevel Gear Assembly - B Note: The taper roller bearings 23 and 21 must be preloaded 0.01 to 0.06 mm to give a rolling torque of 1 to 1.5 Nm. The correct pre-load is achieved by selecting the correct thickness spacer 22. 1

Press fit the outer bearing cups 23 and 21 into the housing 4.

2

Select the largest spacer 22 and assemble with the bearings 23 and 21 in a vice as shown at C. Use a suitable socket Y as a clamping spacer.

3

Tighten the vice and measure the end float on the housing 4. To select the correct size spacer 22 do a calculation as follows: Largest spacer End float example Pre-load required Spacer required

= =

8.00 mm 0.42 mm 7.58 mm 0.04 mm 7.54 mm

4

Select the nearest size spacer 22 and re-assemble in a vice as shown at C. Carefully tighten the vice checking free rotation of housing 4. If the housing becomes stiff to turn by hand stop tightening the vice and fit the next largest spacer.

5

The rolling torque can be measured as a rolling force using a spring balance and cord wrapped around the housing 4 as shown at D. Pull the spring balance until the housing rotates and note the reading, it should be 0.70 to 2 kgf (1.5 to 4.5 lbf) where ‘d’ is 75 mm. If the rolling force is too low re-assemble using the next smallest size spacer.

6

When the correct spacer has been selected remove the assembly from the vice and measure dimension X (shown at E on previous page). Record the measurement.

7

Press the inner bearing 23 onto the bevel gear 19. Fit selected spacer 22

8

Assemble the bevel gear and bearing 23 to the housing 4. Press fit inner bearing 21 onto the bevel gear 19.

9

Use reaction block 892/00915 to hold the assembly in a vice, fit drive flange 17, washer 16, nut 15 and torque tighten using a 46mm socket 892/00912. Do not stake the nut.

S326160

9803/3630

Issue 1


Section F


20 - 8

Assembly


20 - 8

continued

Bevel Gear Assembly - B * 10

Check the bearing rolling torque which should be 0.50 to 1.50 Nm (0.37 to 1.1 lbf ft). Remove the nut 15, washer 16 and drive flange 17.

* 11

Fit new ‘O’ ring 20 and triple lip seal 18. Carefully locate drive flange 17 inside the seal 18. See Seal Renewal.

* 12

Use reaction block 892/00915 to hold the assembly in a vice, fit washer 16, nut 15 and torque tighten using a 46mm socket 892/00912. Do not stake the nut.

* 13


4

C Y

A310100

D

d A310410

9803/3630

Issue 2*


Section F



Bevel Gear Box

20 - 9

20 - 9

Assembly

continued Gear Drive Assemblies to Main Case Make sure you identify the correct location for the drive assemblies the gearbox housing 1. The pinion drive gear assembly fits in the engine side of the housing (position Z). Note: Correct gear meshing and backlash settings are essential for the reliable operation of the gearbox. The settings are obtained by means of variable shim stacks 5. Three methods of shim selection are used depending on the parts renewed during assembly: a b

c

Shim Selection Method A Assembly using all original components. Shim Selection Method B Assembly using complete new gear/bearing assemblies or housing 1. Shim selection method C Shim pack thickness can be calculated by comparing relevant sizes of old and replacement components and then adjusting the shim pack accordingly. This method must be used when renewing taper roller bearings. It can also be of use if some deviation markings are illegible.

Shim Selection Method A 1

As original gears and bearings are being fitted use shims 5 removed during dismantling in their original positions, then see Setting the Backlash.

Shim Selection Method B 1

When assembling using new gear/bearing assemblies it is possible to arrive at nominal shim stack thicknesses (5) by calculation. Due to component tolerencing some ‘deviation’ is built up from base dimensions. These deviations are marked on the relevant components during manufacture.

C

2

Typical locations of deviation markings are shown at C. If some of the markings are not visible then it will not be possible to calculate shim thicknesses. In this event start by fitting 0.50 mm (0.020 in) nominal shims to each gear assembly, see Setting the Backlash.

3

Note down the figures as follows. When noting housing deviations F and J a positive figure becomes a negative and vice versa, eg. -19 becomes +19 in the pinion drive gear calculation shown.

Pinion Drive Gear Assembly Pinion Assembly Deviation D, eg. Pinion Gear Deviation E, eg. + K - see Note 1 = Pinion Housing Deviation F, eg. + = Constant + Shim Stack Thickness =

0 18 18 19 37 40 0.77 mm

Bevel Gear Assembly Bevel Assembly Deviation G, eg. Bevel Gear Deviation H, eg. + L - see Note 2 = Bevel Housing Deviation J, eg. + = Constant + Shim Stack Thickness =

17 60 77 27 104 20 1.24 mm

4

Select shims 5 to make up the nearest thickness for each gear assembly.

Note 1: When fitting replacement pinion assemblies the sum of D and E is marked at K. Note 2: When fitting a replacement bevel assembly the sum of G and H is shown at L Note 3: IMPORTANT - in all cases use the calculations as a starting point. Verify with the backlash and gear tooth mark checks.

H

E

5 6

D

6

1 K 5 2

G

L

A310450

2

Z F

J S310430

9803/3630

Issue 1


Section F


20 - 10

Assembly


20 - 10

continued

Shim Selection Method C a

Renewed taper roller bearings

d

1

Measure and record the thickness of the existing shim stack 5.

1


2

Compare the old and new dimension X (measured during assembly, see the gear assembly procedures).

2

Compare the old and new housing deviations (shown at F (pinion side) and J (bevel side)). When noting housing deviation a positive figure becomes a negative figure and vice versa, e.g. -19 on housing becomes +19 in the calculation below.

e.g. old X = new X = RESULT = SUBTRACT from the relevant shim stack 5. b

40.65 mm 40.32 mm -0.33 mm 0.33 mm

Renewed gear assemblies when deviation markings are illegible. 1


2

Remove the gear and measure the new dimension X.

3

Compare the old and new dimension X (old dimension measured during dismantling, see gear dismantling). e.g. old X new X difference

4

c

Renewed gearbox housing (1)

= = =

40.65 mm 40.32 mm -0.33 mm

e.g. old F = +19 new F = -8 The deviation has altered from +19 to -8, a total of -27 units. SUBTRACT 0.27 mm from the relevant shim stack 5.

0 -8

+19 -27 A314040

If the housing deviation markings are not visible it will not be possible to calculate shim stack adjustment. In this event start by fitting 0.5 mm (0.02 in) nominal shims to each gear assembly, see Setting the Backlash.

Compare the old and new gear deviations (shown at E (pinion gear) and H (bevel gear)). e.g. (pinion gear) old E = 30 (pinion gear) new E = 40 difference = +0.1 mm Add difference from step 3 = -0.33 mm RESULT = -0.23 mm SUBTRACT 0.23 mm from the relevant shim stack 5.

Renewed pinion and bevel gears 1


2

Compare the old and new gear deviations (shown at E (pinion gear) and H (bevel gear)). e.g. (pinion gear) old E = (pinion gear) new E = RESULT = SUBTRACT from the relevant shim stack 5.

X

30 40 +0.1 mm 0.1 mm

9803/3630

Issue 1


Section F


20 - 11


20 - 11

Assembly continued Setting the Backlash Note: Do not fit ‘O’ rings 6 at this stage. 1

Carefully fit the gear assemblies into their correct locations with shims 5, turn the gear shafts slightly to ensure that the gears mesh. Secure each drive in position with three bolts 2.

Note: Ensure the shims are correctly aligned with the nonsymmetrical bolt holes. 2

Hold the pinion drive gear stationary and check the backlash at the bevel gear drive flange (use bolt and lock nut as a reference pin).Take readings at four positions and calculate the average, which should be 0.130 to 0.20 mm (0.005 to 0.007 in).

3

Adjust shims 5 equally from each drive to give the correct backlash.

2

S253170

9803/3630

Issue 1


Section F



Bevel Gear Box

20 - 12

20 - 12

Assembly continued Checking the Gear Meshing 1

Meshing of the teeth should be checked by marking the gear teeth with engineers marking compound and rotating the gears in both directions with the gearbox under load. Check the markings to verify the meshing.

2

Carry out a final check that the gear meshing is correct in both directions under load.

3

When the correct gear meshing is achieved re-check the backlash.

4

Remove drive assemblies, fit new ‘O’ rings 6.

Example showing pinion 10 too deeply in mesh with bevel gear 19.

5

Fit drive assemblies and secure in position with bolts 2, torque tighten.

Increase shim 5 thickness between the pinion drive assembly and the main casing. Decrease shim thickness between the bevel gear assembly and the main case equally to maintain backlash.

Torque Settings

Note: It is recommended that the gearbox is secured to the engine to provide a load.

Item 2 7/15

Nm 85 300

kgf m 8.67 30.60

S253210

lbf ft 62.50 221.25

0

Example showing pinion 10 too far out of mesh with bevel gear 19. Decrease shim 5 thickness between the pinion drive assembly and the main casing. Increase shim thickness between the bevel gear assembly and the main case equally to maintain backlash.

5 2

6

(

6 5

S253200

9803/3630

2 A310460

Issue 1


Section F


21 - 1 *

*

Propshafts

21 - 1

Removal Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.

*


Assembling

P

X

Lubricate sliding joints with JCB HP Grease, align the shafts against identification marks made previously or in the case of a new shaft being fitted, use the manufacturer’s alignment markings. The propshafts must have both ends on exactly 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.

Q

Y

Retaining straps A stretch with use, therefore these straps must always be replaced with new ones. Apply JCB Threadlocker and Sealer to threads of all flange bolts.

Z

R

*

S189610

1

A

S232350

*

2 325440

* Torque Settings Item 1 2

Nm 78 118

kgf m 8 12

lbf ft 57 87

9803/3630

Issue 2*


Section F



Axles

22 - 1

22 - 1

General Description The front axle consists of a centre casing (drivehead) and two axle arms. The drivehead houses the differential gearing and two oil-immersed disc brake units. The axle arms house the halfshafts. Specially shaped spider gears in the differential provide 'torque proportioning'. This means that drive power will be kept on one wheel if the other is slipping. The wheel hubs are connected to the halfshafts through universal joints which drive sun-and-planet gears inside the hubs. * The rear axle works on the same principle as the front axle, but has a single-piece casing which houses the differential and halfshafts. * The rear axle is mounted to the machine through a horizontal trunnion. This allows the wheels to ride up and down over uneven ground, helping to keep the machine, and its load, level. * The front axle is rigidly mounted to the chassis or if a sway machine through a horizontal trunnion. The front and rear axle combinations vary depending on the machine model and variant. * Front Axles Machine 530, 540 530, 535, 540 Sway

Axle Type

Mounting

Hubs

Brakes

Drive Head

SD70 SD70

Fixed - Pad Pivoting - Trunnion

Unbraked Unbraked

Inboard Inboard

Central Central

Axle Type

Mounting

Hubs

Brakes

Drive Head

SD55

Pivoting - Trunnion

Unbraked

No brakes

Offset

* Rear Axles Machine 530, 535, 540 Sway/Non Sway

9803/3630

Issue 3*


Section F

www.WorkshopManuals.co.uk Transmission Axles

22 - 2


22 - 2

*

D

E

E

G

A

F

A

A312050

9803/3630

Issue 2*


Section F


22 - 3 * Front


22 - 3

Fixed Axle (SD70) ! 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. GEN1-1

If the boom is raised, make sure the safety support is fitted. Removing

! 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. TRANS 1-3

1

Disconnect the propshaft coupling from the axle by unscrewing bolts A.

2

Disconnect and plug the hydraulic hoses E to the power track rod.

3

Slacken off the roadwheel retaining nuts then raise and support the front end of the machine on axle stands or blocks positioned under the chassis. Remove the front roadwheels.

4

Remove the front mudguards. Undo the bracket retaining nuts F at the steering trunnions.

5

Disconnect the brake hose at the axle. Blank off the exposed connections.

6

Support the axle on a trolley jack.

7

Unscrew axle mounting nuts D and remove the bolts and washers.

8

Lower the axle down from the machine, tie up the proximity switch G.

9

Remove the axle from the machine.

Replacing Replacing is generally the reverse of the removal sequence. Set the proximity switch, see Section C, Contents. Grease the axle pivot before driving the machine. Refit the road wheels and carry out the tightness checks as detailed in the Service Manual and Operator Handbook. Bleed the brake system, see Section G Contents, and steering system, see Section H, Contents, before driving the machine. Torque Settings Item A D F

Nm 78 600 98

kgf m 8 60 10

lbf ft 57 440 72

9803/3630

Issue 2*


Section F


22 - 4


22 - 4

*

B

G B

B

G J

B

J

J

B B

C

J C K

C

E D H

A

F

A A312090

9803/3630

Issue 2*


Section F


22 - 5 *


22 - 5

Front Sway Axle (SD70) (N.Am only) ! 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. GEN1-1

Replacing Replacing is generally the reverse of the removal sequence. Make sure you re-fit dowels J together with any shims in their original positions. Make sure that the axle oscillates freely before final tightening of the fixing bolts. Set the proximity switch, see Section C, Contents.

If the boom is raised, make sure the safety support is fitted. Removing

! WARNING

Grease the axle pivot before driving the machine. Refit the road wheels and carry out the tightness checks as detailed in the Service Manual and Operator Handbook.

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.

Bleed the brake system, see Section G Contents, and steering system, see Section H, Contents, before driving the machine.

TRANS 1-3

Torque Settings

1


2

Disconnect and plug the hydraulic hoses G to the power track rod.

3

Slacken off the roadwheel retaining nuts then raise and support the front end of the machine on support stands or blocks positioned under the chassis. Remove the front roadwheels.

4

Remove the front mudguards. Undo the bracket retaining nuts F at the steering trunnions.

5

Disconnect the brake hose at the axle. Blank off the exposed connections.

6

Undo bolt D and remove pivot pin E.

7

Undo the sway ram pivot bracket mounting bolts H. Lift away the bracket. Tie the proximity sensor mounting bracket K clear of the axle.

8


9

Undo the six trunnion bolts B/nuts C.

Item A B/C H F

Nm 78 476 600 98

kgf m 8 48 60 10

lbf ft 57 352 440 72

10 Remove the axle from the machine. Be sure to retrieve dowels J. If shims are fitted record their positions.

9803/3630

Issue 2*


Section F



Axles

23 - 1

B

23 - 1

G

J

C J

J

C

J G

C C

C

E

A A F A312040

9803/3630

Issue 1


Section F



Axles

23 - 2

23 - 2

Rear Axle (SD55) Replacing

! 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.

Replacing is generally the reverse of the removal sequence. Make sure you re-fit dowels J together with any shims in their original positions. Make sure that the axle oscillates freely before final tightening of the fixing bolts. Set the proximity switch, see Section C, Contents.

GEN1-1

Fully retract the boom. Raise the boom and fit the safety support.

Grease the axle pivot before driving the machine.

1


Before fitting the S.L.I./L.M.I. transducer remove any rust, dirt or paint from transducer mounting faces. Make sure that the mounting faces are flat and level, remove any burrs. Place the transducer in position, check that the bolt holes align and the mating faces are flush.

2

Disconnect and plug the hydraulic hoses G to the power track rod.

Secure transducer in place with bolts B, torque load and tighten evenly.

3

Remove the steering proximity switch. Remove the cover F and then the bracket. Tie up clear of the axle.

Refit the road wheels and carry out the tightness checks as detailed in the Service Manual and Operator Handbook.

4

Unscrew bolts B securing the Safe Load Indicator (S.L.I.)/ Load Moment Indicator (L.M.I.) transducer and tie up clear of the axle.

Bleed the brake system (see Section G, Contents) and the steering system (see Section H, Contents) before driving the machine.

5

Slacken off the roadwheel retaining nuts then raise and support the rear end of the machine on axle stands or blocks positioned under the chassis. Remove the rear roadwheels.

Before using the machine carry out S.L.I./L.M.I. Adjustment, see Section C, Contents.

6

Remove the rear mudguards. Undo the bracket retaining nuts E at the steering trunnions.

7


Item A B C E

8

Undo the six trunnion nuts C.

9

Lower the axle clear of the mounting yoke and withdraw from the machine. Be sure to retrieve dowels J. If shims are fitted record their positions.

Removing

Torque Settings Nm 78 70 476 98

kgf m 8 7.1 48 10

lbf ft 57 51.6 352 72

9803/3630

Issue 2



Section F


* Front Axle (SD70)

24 - 1

24 - 1

*

16

7

4 5

6

15

6

13

2 9 12

14

34

10 11 8

43

20

3 17

D 19

1

27 28

18

24

29 25

31

23

32 30

21 22

26 A312070

9803/3630

Issue 3*


Section F

www.WorkshopManuals.co.uk Transmission * Front Axle (SD70)

24 - 2 *


24 - 2

Hub - Dismantling

12

Remove circlip 15 to separate the annulus ring 16 from the annulus carrier 13.

The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the axle.

13

Pull off the bearing carrier 17 together with the outer bearing cone and its bearing cup 18. Withdraw the inner bearing cup 19 from the inboard side of the carrier.

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.

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.

! WARNING

Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN 1-1

1

Disconnect the steering track rod. Drain oil from the hub.

X

Note: The illustration shows a typical axle. 2

Remove screws 1.

3

Lever the planet gear carrier 2 off the bearing carrier. Remove ‘O’ ring 3.

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 7.

A258390

5

Pull off the planet gear 4.

6

The driveshaft thrust pad 8 is drilled and tapped M6 for removal purposes.

7

14

Pull off the inner bearing 19 (see Note at step 13).

Note: The inner bearing 19 and oil seal 20 may withdraw with the bearing carrier 17. 15

Remove and discard the combination seal 20. When assembling the axle, a new combination seal must be used.

Remove circlip 9 to allow the sun gear 10 to be slid off the drive shaft 34.

16

Mark position of top and bottom trunnions 28 and remove. Withdraw the hub carrier 30.

8

To remove the ‘Verbus Ripp’ bolts 12, it is necessary to remove the spacer 11. Revolve the spacer with a suitable drift to align the holes in the spacer with the space between the bolts.

Note 1: Trunnions may be removed easily by pumping grease through the grease nipple.

9

Using two dowels and two heel bars, remove the spacer 11.

10

Remove the ‘Verbus Ripp’ bolts 12 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 with a six sided socket. Discard the Verbus Ripp bolts after removal.

11

Note 2: Earlier axles are fitted with shims. Remove shims and retain for assembly. 17

Use adaptor 993/59500 with slide hammer tool 892/00224 and remove driveshaft seal 21 and needle roller bearing 22 from the hub carrier 30.

18

Use a puller to remove the trunnion seal 31 and bearing 32.

Ensure the ring dowels 14 remain seated in the annulus carrier 13.

* 19 Withdraw drive shaft 34 and prise out drive shaft inner oil seal 23.

Using 2 high grade M14 bolts as jacking screws, remove the annulus carrier 13.

20 Remove circlip 24 and remove bearing 25 using tool 892/00225.

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.

21

If there has been a component failure, remove all traces of debris and clean the magnetic drain plug D.

Note: When refitting the drain plug, torque to 35 - 40 Nm (26 - 30 lbf ft).

9803/3630

Issue 4*



Section F


* Front Axle (SD70)

24 - 3

24 - 3

*

16

7

4 5

6

15

6

13

2 9 12

14

34

10 11 8

43

20

3 17

D 19

1

27 28

18

24

29 25

31

23

32 30

21 22

26 A312070

9803/3630

Issue 3*


Section F



* Front Axle (SD70)

24 - 4

24 - 4

Hub - Assembly Note: Refer to Salvage/Repair (this section) for any information relevant to this assembly, especially data on oil seal variants. 1

10

Fit a new combination oil seal 20. Do not lubricate before fitting. Using the service tool and spacer drive the seal squarely into the carrier until the locating lip is flush as shown at A.

Tap drive shaft inner bearing 25 into position and s e c u r e with circlip 24.

2

Fit new oil seal 23. Pack grease between lips of seal.

3

Fit drive shaft 34, taking care to locate inner end into splines of differential gears.

4

Press new trunnion seal 31 into position followed by the bearing 32. Grease bearing and oil seal before fitting to axle.

5

Fit driveshaft needle roller bearing 22 to the hub carrier 30. Pack the cavity between the oil seal lips with grease and then fit the seal 21.

6

Locate hub carrier and fit bottom trunnion 8. Apply JCB Threadlocker and Sealer to the bottom trunnion bolt threads 27, fit and tighten to 98 Nm (72 lbf ft). Fit top trunnion 28 and leave top trunnion bolts 27 finger tight.

7

Attach a spring balance to track rod swivel as shown and note the reading. Tighten the top trunnion bolts 27 to eliminate end float but no bearing pre-load, ie no

A

A272180

11

Fit the bearing carrier 17 onto the axle arm 24. Lightly oil the outer wheel bearing race 18. Fit the bearing 18 onto the axle arm 30. Rotate the bearing during fitting.

12

Assemble the annulus ring 16 to the annulus carrier 13. Secure with the circlip 15.

13

Fit annulus assembly in the same angular position as removal (see Note, Step 11, Dismantling) 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. 14

To measure drag seal rolling force: -

Use a spring balance and cord wrapped around the planet 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.

160251

increase in spring balance reading. Note: Earlier axles are fitted with shims 29. Measure gap at top trunnion and subtract 1 mm (0.040 in) to give shim thickness (bearing pre-load). For example: Gap = 1.55 mm (0.061 in) less 1.00 mm (0.040 in) Shim =

0.55 mm (0.021 in)

Note 1: If the gap measures 1 mm, then no shim is required. Note 2: On later axles without shims, if, after adjustment the bearing pre-load is unattainable fit new bearings. S248870

8

9

Refit top trunnion 28. Apply JCB Threadlocker and Sealer to the top trunnion bolt threads, fit and tighten to 98 Nm (72 lbf ft). Check spring balance reading which should be 4.5 kgf (10 lbf) more than the reading recorded at step 7.

15

Remove the planet gear carrier 2 and tighten M14 Verbus Ripp bolts 12 to 320 Nm (236 lbf ft, 33 kgf m) and then measure rolling force - see step 16.

Lightly oil the inner wheel bearing 19. Assemble the inner and outer bearing cups, and the inner bearing cone into the bearing carrier 17.

9803/3630

Issue 2



Section F


Front Axle (SD70)

24 - 5

24 - 5

16

7

4 5

6

15

6

13

2 9 12

14

34

10 11 8

43

20

3 17

D 19

1

27 28

18

24

29 25

31

23

32 30

21 22

26 A312070

9803/3630

Issue 2*


Section F

www.WorkshopManuals.co.uk Transmission Front Axle (SD70)

24 - 6


24 - 6

Hub - Assembly (continued) 16

To measure rolling force: -

Refit the planet gear carrier 2 - DO NOT FIT THE SUN GEAR. Use a spring balance and cord wrapped around the planet gear carrier as shown. Pull the spring balance so that the hub rotates and record the reading.

-

To get the rolling force, subtract seal drag rolling force (see step 14) from reading obtained at this step, the result should be 64 to 117 N (14 to 26 lbf).

-

If the resulting figure is outside these limits check: the seal is fitted correctly; and/or renew bearings if necessary; and/or new fitted components.

-

Remove planet gear carrier 2.

X

S258230

20

S248870

17

Press the drive shaft thrust pad 8 (chamfered side lowermost) into the recess in the planet carrier 2.

18

Fit new planet gears 4 in place of any that were removed. (See step 4, Dismantling). Secure with circlip 7.

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. 19

Fit the planet gear carrier 2 onto the bearing carrier 17, turning it slightly to engage the gear teeth and aligning the two tapped holes in the planet gear carrier with their mating holes in the bearing carrier. (The tapped holes are diametrically opposite one another.) Ensure the planet gear butts fully against the bearing carrier. Refit screws 1. Torque tighten to 56 Nm (41 lbf ft).

Note: Do not strike the centre of the planet gear carrier when fitting as this may dislodge the driveshaft thrust pad 8 fitted at step 17. Re-fill hubs with the correct grade oil (See Lubricants and Capacities - Section 3.) * Note: When refitting the drain plug, torque to 35 - 40 Nm (26 - 30 lbf ft).

Fit spacer 11 and slide the sun wheel 10 onto the driveshaft 34 and secure with circlip 9. Fit a new ‘O’ ring 3 in position X.

Note: The sun gear must be fitted with the 1.5 mm (0.060 in) x 45° chamfer inboard.

9803/3630

Issue 2*


Section F


24 - 7


24 - 7

3A

328020

Y

S255900

9803/3630

Issue 2


Section F


24 - 8


24 - 8

Brakes (Without Controlled Back-off) Dismantling

Assembly

The following procedure shows the axle removed from the machine, however, the brakes may be accessed without removing the complete axle.

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

Assemble the friction plates and counterplates 2 onto the carrier 3A. If the original brake pack is being reused, 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.


1

*

Disconnect track rod end. Disconnect and plug hydraulic hoses and remove steer rams. Support the axle arm. If working with the axle in situ on non-sway machines, the axle mounting bolts must be removed on the side to be worked on.

2

Remove Durlok bolts 1. Use a heavy duty socket 892/00818 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

5

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.

* 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. Later axles are fitted with a different type of brake carrier 3A. Brake carrier 3 should be replaced by brake carrier 3A on both sides of the axle during a brake overhaul. 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 3A faces away from the drive head. Return re-used counterplates to their original positions. Push the brake pack fully home.

6

Apply JCB High Strength Gasketing to the mating face of the drive head, and JCB Threadlocker and Sealer to the threads of bolts 1. (Use new Durlok bolts). Locate the axle arm onto the drivehead, with the embossed word 'TOP' on the axle arm uppermost.

7

Fit bolts 1 and torque tighten.

Remove the circlip 4. If the brake pack is to be re-used, note the positions of the plates before removing them.

Note: The plate carrier 3 has an internal chamfer at the end which faces away from the drivehead. 6

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.

Wear limit of friction plates is to the depth of circumferential grooves X on early machines (or crosshatching Y on later machines). Check all plates for flatness and damage. (Some wear or polishing 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.

9

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: Check the grade of bolts fitted. Grade 8.8 should be tightened to 244 Nm (178lbf ft, 24.9 kgf m), grade 12.9 should be tightened to 400 Nm (295 lbf ft, 40.8 kgf m).

9803/3630

Issue 2*


Section F


24 - 9

*


24 - 9

Front Axle - SD70

8

7 9

16

15

5 11

10 17

13 14 12

3

2 B A

2 4

1

6

378122

9803/3630

Issue 4*


Section F

www.WorkshopManuals.co.uk Transmission * Front

24 - 10


Axle - SD70

24 - 10

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.

9803/3630

Issue 4*


Section F


24 - 11

*


24 - 11

Front Axle - SD70

8

7 9

16

15

5 11

10 17

13 14 12

3

2 B A

2 4

1

6

378122

9803/3630

Issue 2*


Section F

www.WorkshopManuals.co.uk Transmission * Front

24 - 12

Axle - SD70


24 - 12

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: 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.

9803/3630

Issue 3*




www.maskinisten.net

Section F



Front Axle (SD70)

26 - 1

26 - 1

Drive Head-Dismantling

1

Note 1: As the drivehead cannot be dismantled in situ, the complete axle must be removed from the machine. Note 2: When dismantling, note carefully the POSITION and ORIENTATION of all components. These may differ slightly from those shown. 1

After removing the axle arms, position the drive head as shown, with the crownwheel at the top. For coupling removal see Section F, Contents, Renewing the Pinion Seal. 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).

2

S256050

3

! 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

S256060

4

Lift out the crownwheel/differential assembly.

4

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.

S256070

5

Withdraw the pinion.

6

Withdraw the pinion seal and outer bearing cone.

7

5

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

7

6 S256080

9803/3630

6 Issue 1


Section F



Front Axle (SD70)

26 - 2

26 - 2

Drive Head-Dismantling (cont'd) 8

Remove and discard the pinion spacer.

9

Pull off the bearing cone.

9

8 S256090

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

If required, remove the crownwheel and discard Verbus Ripp bolts. Note: For axles with Limited Slip Differential, see Limited Slip Differential.

!

@

@ 256100

9803/3630

Issue 1


Section F


26 - 3


26 - 3

Drive Head-Assembly Pinion Depth For general guidance on crownwheel and pinion adjustment, see Section F, Contents, 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

S184400

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: Mounting distance figure B is also etched on the rear face of some pinions.

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.

B

S256110

Example (Dimensions in mm) Dimension A Add tool depth Total

0.25 + 30.01 30.26

Add dimension B if positive. (Subtract if negative.) Total

+ 0.01 30.27

Add dimension C if negative. (Subtract if positive.) Total

+ 0.01 30.28

Standard Value Less total above SHIM THICKNESS

31.19 - 30.28 0.91

C S256120

9803/3630

Issue 1


Section F



Front Axle (SD70)

26 - 4

26 - 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. 7

8

9

8

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 and Sealer to the threads of bolts, then fit and torque - tighten to 56 Nm (42 lbf ft, 6 kgf m). Check the gears for free rotation.

7

7

Fit the pinion inner bearing cone and a new solid spacer - see Salvage/Repair, Fitting a New Spacer to Drive Head, this section. Carry out the instructions given there, then continue assembly from step 15 below.

256100

9

9

If a suitable solid spacer or the tools required are not available, fit a new collapsible spacer onto pinion and continue with steps 10 to 14 below.

S256090

10

Fit the pinion inner bearing cup, together with the required thickness of shims to give correct pinion depth, see Pinion Depth, steps 1 to 6. To ensure the cup is fitted square, use a suitable puller assembly. Do not use a hammer. Fit the outer bearing cup.

11

Insert the pinion into its bore. (Before inserting, ensure that the pinion matches the crownwheel.) The code numbers etched on the pinion end face and the crownwheel perimeter should be the same.

12

Fit the pinion outer bearing cone and the seal. Pack between the lips of the seal with grease before fitting.

!

0 0

@ 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

9803/3630

Issue 1


Section F



Front Axle (SD70)

26 - 5

26 - 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

Apply JCB High Strength Gasketing 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.)

*

& ^

Note: To measure the backlash, use a magnet drilled and tapped to accept a length of rod threaded 6 mm on one end. Position the magnet in between the crownwheel locking bolts as shown at A. 17

18

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.)

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.

S256140

A

Note: When refitting cap screws, clean the threads with a wire brush and coat the threads with JCB Threadlocker and Sealer. New capscrews are supplied with JCB Threadlocker and Sealer already applied as a ‘patch’ on the thread. 19

Check the meshing of the crownwheel and pinion gears (see Crownwheel and Pinion Adjustment).

S256150

9803/3630

Issue 1




www.maskinisten.net

Section F

www.WorkshopManuals.co.uk Transmission *Rear Axle (SD55)

29 - 1 *


29 - 1

Hubs Dismantling and Assembly The SD55 rear axle features unbraked wheel hubs. The dismantling and assembly is the same as SD70 front axles. See Front Axle (SD70) - Hub - Dismantling, Hub Assembly.

9803/3630

Issue 2*


Section F

www.WorkshopManuals.co.uk Transmission *Rear Axle (SD55)

30 - 1


30 - 1

*

338240

20

3 23 22 2 21 19 18

24 1

16 338250

9803/3630

Issue 2*


Section F

www.WorkshopManuals.co.uk Transmission Rear Axle (SD55)

30 - 2


30 - 2

Drive Head Dismantling

! WARNING A raised or 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 hydraulic 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

Note: When dismantling, note carefully the POSITION and ORIENTATION of all components. These may differ slightly from those shown. 1

Drain the oil from the drive head. Remove the propshaft.

2

To remove the drive head it is necessary to withdraw both drive shafts from the axle (see Hub, Dismantling and Assembly) and remove the power track rod (see Steering, Section H).

3

Remove the drive head carrier screws 1. Mark the installation position of drive head carrier 2 relative to the axle housing.

4

Remove the drive head carrier from the axle housing.

5

Pull out the roll pins 3 and remove the castellated nuts 4. Remove the outer races of bearings 5 and 6 from the drive head carrier bores.

6

Remove inner bearing races of 5 and 6.

7

Remove differential assembly 8 from carrier.

8

Loosen the differential case half bolts 7 and pull the case halves 8A and 8B apart. Remove the axle bevel gears 9, the differential bevel gears 10, trunnion pin 11 and thrust washers 12 from the case halves.

* 18

Remove spacer 24 from drive pinion 20. Prise taper roller bearing 22 to raise it sufficiently to insert bearing pullers. Pull the bearing from the pinion shaft.

Assembly 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. 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).

2

Fit new pinion head bearing cone 22 onto pinion 20.

*3

Fit a new solid spacer 24 onto pinion 20. See Fitting a New Spacer to Drive Head, this section. Carry out the instructions given there, then continue assembly from step 6 below. If a suitable solid spacer or the tools required are not available, fit a new collapsible spacer 24 onto pinion 20 and continue with steps 4 and 5 below.

4

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. Fit drive yoke 18 using a new stake nut 16.

5

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 - 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.

9

Remove the thrust washers 13 from both case halves.

10

Pull off the bearing 6 from case half 8A.

11

Remove the screws 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.

Note 2: If the specific rolling torque is exceeded, the collapsible spacer will be distorted. Renew the spacer and start again.

13

Remove the drive yoke.

6

14

Drive pinion shaft 20 out of drive head carrier 2.

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).

15

Prise shaft seal 19 out of the bore.

7

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.

Position differential half case 8B onto half case 8A, aligning the match-mark letters (see Note 1 above). Apply JCB Threadlocker and Sealer to the threads of bolts 7, then fit and torque tighten to 28 Nm (21 lbf ft, 3 kgf m). Check the gears for free rotation.

8

Fit crownwheel 15 using new Verbus Ripp bolts 14 tightened to 94 Nm (69 lbf ft, 9.59 kgf m).

9803/3630

Issue 3*


Section F

www.WorkshopManuals.co.uk Transmission Rear Axle (SD55)

30 - 3


30 - 3

20

3 23 22 2 21 19 18

24 1

16

9803/3630

Issue 1


Section F


30 - 4

Rear Axle (SD55)


30 - 4

Drive Head (cont’d) Assembly (cont’d) *9

Locate crownwheel assembly (without bearings) into housing.

10

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.

11

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.

12

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.

13

Check tooth marking, see Crownwheel and Pinion Adjustment.

Pinion Depth Setting Procedure Place new pinion head bearing assembly on a flat surface and position bearing cup 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.

S184400

14

15

Apply JCB Multi-Gasket 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 56 Nm (42 lbf ft, 6 kgf m). Reassemble both driveshafts and hub assemblies (refer to Hubs, Dismantling and Assembly). Re-fill the hubs and differential with the correct grade of oil (see Lubricants and Capacities, Section 3). Refit the propshaft.

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. 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. Subtract the total of the above figures form the standard value of 31.19 mm. The result will be the thickness of shims required behind the pinion head bearing cup. Example (all dimensions in millimetres) Cup depth Gap A Bearing depth Pinion deviation (+ 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 Crownwheel and Pinion Adjustment for gear meshing checking procedure.

9803/3630

Issue 3*


Section F


33 - 1

Crownwheel and Pinion


33 - 1

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.

A290520

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.

A290530

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.

A290540

9803/3630

Issue 1




www.maskinisten.net

Section F




36 - 1

36 - 1

5 6

1

7 8

9 13

14

12 9

3 10

8

7 6

11 10

15

2 4 S212800

S171530 S212790

9803/3630

Issue 1


Section F




36 - 2

The numerical sequence shown on the illustration is intended as a guide to dismantling.

36 - 2

Friction Plate Wear Limits

Dismantling

Measure the thickness of the wear material which must not be less than 1.25 mm (0.049 in.)

Mark the two differential halves before dismantling, for subsequent assembly.

Check the condition of the friction material which should be even over both surfaces.

Note the relative positions of friction and counter plates before dismantling, they must be fitted in the same positions.

If in doubt fit a new set of friction and counter plates.

If worn the friction and counter plates must be renewed as a complete set. Assembling 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 shims 6 at this point. Align the two halves of the differential assembly with the marks made during dismantling. Assemble using bolts 3. Shimming must be carried out whenever new friction and counter plates are fitted. With new friction and counter plates the end float should be 0.1 to 0.2 mm (0.004 to 0.008 in). After initial bedding in the normal end float is between 1.0 to 2.0 mm (0.04 to 0.08 in) depending on the time in service. If 3.5 mm (1.14 in) is exceeded check the fiction wear. material which must not be less than 1.25 mm (0.049 in). Determine shim value by either a dial test indicator or feeler gauges, refer to the relevant illustration: 1

With two screw drivers or suitable levers, gently apply pressure to side gear 10 via the clutch pack as shown. Measure and note the end-float of the side gear.

2

Turn the differential over and repeat step 1 for the second side gear. Measure and note the end-float of the side gear.

3

Dismantle the differential assembly, refer to measurements taken at steps 1 and 2 add shims 6 to give the required end float.

Repeat steps 1, 2 and 3, until the end float is correct, torque tighten bolts 3 to 56 Nm (41 lbf ft). Fit crownwheel 2 using Verbus Ripp bolts 1, torque tighten to 166 Nm (122.5 lbf ft).

9803/3630

Issue 1


Section F 45 - 1

www.WorkshopManuals.co.uk Transmission Salvage/Repair


45 - 1

Introduction Transmission components are the subject of continuous development and improvement. Such development can affect the service procedure for transmission assemblies. This section clarifies the design variants relative to component assembly. In addition some approved salvage procedures are included to help avoid unnecessary component renewal.

9803/3630

Issue 1


Section F


45 - 2


45 - 2

Drive Shaft Outer Oil Seal - Variants The drive shaft outer oil seal is shown at F. An upgraded oil seal is used on later axles as shown at A. The old seal is shown at B. Note: The new seal is 3.5 mm thicker than the old type seal (because an extra sealing lip is incorporated). It therefore will not replace the previous seal in the existing swivel housing without fouling on the drive shaft yoke and causing seal failure. Oil Seal Replacement 1

Note: The majority of seal failures are caused by either incorrect fitting, marks on the shaft sealing surface or seal housing. High pressure water washing jets directed at the seal can cause contamination and premature failure. By identifying the cause, repeat failures will be avoided.

C

Before fitting the seal, measure dimension X.

18.514.5

A

If dimension X is 33 mm, fit the new seal A to a depth of 14.5 mm as shown at C. If dimension X is 25 mm, fit the old type seal B to a depth of 10 mm as shown at D. Note: If a new type seal is not available, the old type seal B can be fitted in the new type swivel housing. The new seal cannot be fitted in the old type swivel housing. When fitting the old seal B in the new type housing, drive it in until dimension Y is 14 to 14.5 mm (as shown at E). If this seal is driven in further, it will contact the bearing and damage to the seal can be caused. 2

Using clean JCB HP Grease, lightly lubricate the bearing and the seal internally. Ensure that face of seal is not damaged, bent or buckled during fitting.

X (33) 64.5

A312130

D

15 10

B

F

X (25) 60

E

A312120

Y (14-14.5)

B

A

B

X (33) 64.5 A312110

9803/3630

A312140

Issue 1


Section F


45 - 3


45 - 3

Drive Shaft Inner Oil Seal - Variants The drive shaft inner oil seal is shown at X. An upgraded oil seal is available with double sealing lips as shown at A. The old seal is shown at B.

X

A

B

A312150

Oil Seal Replacement 1

Inspect the drive shaft seal surface for wear or pitting. Should wear or damage be present see Drive Shaft Salvage - After Oil Seal Failure. If the shaft is serviceable proceed as follows: a

Determine the installation requirements of the new seal. Measure dimension V from shoulder W to circlip Z. If dimension V is 16 to 16.3 mm (0.63 to 0.64 in), fit the new seal protruding 2.0 mm (0.080 in) as shown at C. If dimension V is 17.3 to 17.5 mm (0.68 to 0.69 in), fit the new seal flush with the end of the housing as shown at D.

D

C V

Z

V

W

Z

W

A312160

9803/3630

Issue 1


Section F 45 - 4


Drive Shaft - Salvage After Oil Seal Failure


45 - 4

V

The inner drive shaft oil seal X can fail due to drive shaft wear or damage. The drive shaft can be made serviceable by fitting a wear sleeve. 1

If during seal replacement, drive shaft wear is found to be present, check the drive shaft diameter at Y on an unworn section away from the seal track. If the diameter is 46.165 to 46.145 mm (1.818 to 1.817 in) a wear sleeve can be fitted. If the diameter is outside these limits, the sleeve cannot be fitted successfully and the shaft must be renewed.

X

If the wear sleeve A is to be fitted obtain a sleeve, special bearing C and special seal B. Proceed as follows: A312170

2

Remove burrs or rust using an oil stone or emery cloth, taking care not to reduce the overall shaft size. Degrease the wear sleeve and shaft, apply JCB Retainer (High Strength) to the shaft.

Note: The sleeve must be expanded before fitting by heating to 100 - 110 °C (212 - 230 F). Take precautions to prevent the danger of personal injury by burning. Wear gloves and protective overalls.

B C A

After pre-heating, use a suitable tube to press or tap the wear sleeve A onto the shaft, internal chamfered end first, until fully located against the shaft shoulder. Note: If the sleeve is not a tight fit on the shaft, the shaft must be renewed. A312180

3

Remove the old inner drive shaft seal, circlip and bearing.

4

Fit new special size bearing C, the old circlip and new special size seal B. If dimension V is 16 to 16.3 mm (0.63 to 0.64 in), fit the new seal protruding by 2 mm (0.080 in).

Y

If dimension V is 17.3 to 17.5 mm (0.68 to 0.69 in), fit the new seal flush with the end of the housing. 5

Refit the drive shaft taking care not to damage the seal when fitting the shaft. Complete the repair.

If the wear sleeve has to be removed from the shaft, use the following method: 1

Place the sleeve A horizontally on an anvil or suitable hard surface as shown at Z. Hammer the sleeve whilst rotating the shaft until the sleeve becomes oval and will slide off the shaft. Protect your eyes when hammering. Wear safety glasses or goggles.

Z A

9803/3630

Issue 1


Section F



Salvage/Repair

45 - 5

45 - 5

Axle and Gearbox Drive Shaft Flange Salvage After Oil Seal Failure When rectifying oil leaks from drive shaft flanges (typically shown at X) always ensure that the cause of seal failure is identified, performing additional service as required. This will ensure maximum service life from replacement seals. Oil leaks can be caused by one or more of the following: 1

Dirt ingress/contamination Dirt can enter an oil seal if the unit or flange is not thoroughly cleaned before removal and before fitting a new seal. Contamination can also occur if high pressure water washing jets are directed at oil seals.

2

X

Damage to the seal housing when removing seal Take care when removing seals and avoid damaging the housing. On the outer diameter small scratches/marks can be cured by using a silicon sealant on the seal outer diameter. For excessive damage fit a new component.

3

Oil seal damaged when fitting Check that the oil seal is not damaged, distorted or the lips cut or torn. When fitting an oil seal use a suitable tool or tube that does not touch the seal lip and fully supports the casing of the seal without distorting the seal during fitting. Lubricate the seal’s external and internal diameters sparingly with JCB HP grease and check the spring was not displaced during fitting.

4

Oil seal not fitted square After fitting, measure the oil seal depth B in four places as shown at A, if the depth varies by more than 0.50 mm (0.0195 in) carefully tap the new seal unit square or fit another seal. Continued...

X

A312210

A A

A A

B 9803/3630

Issue 1


Section F


45 - 6


45 - 6

Axle and Gearbox Drive Shaft Flange Salvage After Oil Seal Failure (continued) 5

Incorrect oil seal fitted Refer to the parts catalogue for correct part numbers, location. If in doubt measure the flange diamaeter D, (typical illustration).

6

Poor seal yoke/flange surface finish When the leak is a seepage around the seal and if none of the other points are evident, check the yoke/flange surface carefully for damage.

D

Restoring Surface Finish Light damage, scratches/marks of the surface finish can be restored. (Marks or scratches barely visible by eye can allow hot oil to leak past the seal.) If the surface is excessively damaged or worn, fit a new component. Restore by carefully polishing with 800 or finer grade abrasive grit paper C. Use clean hydraulic oil as a lubricating and cutting fluid while polishing to prevent scoring or scratches. The recommended procedure to polish a component is to mount in a lathe, rotate to 100 rpm approx. and gently apply a strip of 800 or finer abrasive grit paper and a film of hydraulic oil. Note: Take care if polishing by hand when finishing to keep abrasive paper clean. Do not rotate the paper and the component in such a way as to create scratches or a spiral mark, which could ‘screw’ a small oil film under the seal lip. Thoroughly clean all parts before and after polishing.

C A311200

9803/3630

Issue 1


Section F



Salvage/Repair

45 - 7

45 - 7

Hub Bearing Carrier Oil Seal - Variants Note: Fitting the latest type seal to an earlier axle (prior to April 95) without using the service tool will cause damage to the seal.

The hub bearing carrier oil seal is shown at W. An upgraded oil seal is available as shown at E. Measure the dimension between the wheel bearing face Y and the outer face of the wheel bearing carrier Z. a

b

If the dimension is 25 to 26 mm (A) fit the oil seal using service tool (part number 892/00891) with the spacer D until the oil seal is level with the wheel bearing carrier face Z.

The previous type seal must not be fitted to the later type wheel bearing carrier (no chamfer at X), as the seal will fail in service. Note: The majority of seal failures are caused by either incorrect fitting, marks on the shaft sealing surface or seal housing. High pressure water washing jets directed at the seal can cause contamination and premature failure.

Prior to April 95 the distance will be 28 to 30 mm (B). For these axles fit the seal to a depth of 3 mm by using the service tool C (part number 892/00891), without spacer D.

A

W

25-26 MM

X

Z

Y

C D

E

B

28-30 MM

X

Z

A312230

9803/3630

Issue 1


Section F


45 - 8


45 - 8

Renewing the Pinion Oil Seal The pinion oil seal 4 may be renewed without removing the axle from the machine.

3

Remove the seal 4 and fit a new one. Pack between the lips of the new seal with grease before fitting. Check bearing and seal contact surfaces of drive flange 1 for wear, renew flange if required

4

Fit the coupling yoke, its washer and a new stake nut:

! 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.

4.1 Using Service Tool 892/00812, tighten the nut to 200 Nm (148 lbf ft; 20.4 kgf m).

GEN-001

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).

1

4.3 If necessary, progressively torque tighten nut to achieve correct rolling torque.

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

2

Remove the roadwheels and uncouple the axle propshaft. Mark relative positions of the pinion shaft 5 and nut 2 with a scriber. Measure the axle rolling torque and record the reading. Using Service Tool 892/00812, remove the drive flange 1 together with its stake nut 2 and washer 3. Check whether a collapsible or solid spacer is fitted.

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 removed and a new spacer fitted. See Fitting a New Spacer to Drive Head, this section. 4.4 Stake the nut using a square ended staking tool.

If a collapsible spacer is fitted, carry out steps 3, 4 and 6 following. If a solid spacer is fitted, carry out step 3 then steps 5 and 6 following.

Note: Later axles have a combined stake nut and washer. If this is fitted in service, the separate washer must be discarded.

5

S203310

9803/3630

Issue 1


Section F


45 - 9


45 - 9

Renewing the Pinion Oil Seal (continued) 5

Fit the coupling yoke, its washer and refit the old stake nut temporarily: 5.1 Using a torque wrench, determine the torque required to align the lines scribed in step 1. Remove and discard the old nut. Fit a new stake nut using the torque setting established. 5.2 After tightening, re-check the rolling torque which should be no more than 0.5 to 1.0 Nm (0.37 to 0.74lbf ft; 0.05 to 0.1kgf m) higher than measured in step 1. 5.3 Continue tightening to a minimum torque of 250 Nm (185 lbf ft; 25.5 kgf m) and maximum of 300 Nm (222 lbf ft; 30.6 kgf m), progressively tightening to achieve a rolling torque not exceeding 1.0 Nm (0.74 lbf ft; 0.1 kgf m) higher then measured in step 1. 5.4 If the rolling torque is too high or the torque on the pinion nut is not achieved, rebuild the differential using a new spacer, see Fitting a New Spacer to Drive Head, this section.

6

Refit the roadwheels and couple the propshaft.

9803/3630

Issue 1


Section F


45 - 10


45 - 10

Fitting a New Spacer to Drive Head

Installation of a Solid Spacer

All JCB axles from March 2000 with ‘plug in’ type driveheads as shown are built using a solid spacer instead of the collapsible spacer. All older axles with collapsible spacers can be fitted with solid spacers which is the preferred option. However, in the absence of the special tools required or of the correct size solid spacer it is acceptable for a collapsible spacer to be fitted.

1

Dismantle differential, clean and inspect parts, see Drive Head - Dismantling for the appropriate axle.

2

Select correct shim 29 value for pinion head bearing 28 see Drive Head - Assembly for the appropriate axle.

3

Fit the pinion head bearing cap and shims into the drive head casing.

4

Install pinion and bearings into the drive head casing. Install largest available solid spacer 30 e.g (14.20 mm A) and fit pinion tail bearing 26/27 (lightly oiled). Do not fit the oil seal 25 at this stage.

5

Fit special tool sleeve B and special pinion shaft adapter C. Tighten adapter C to approximately 50 Nm (36.9 lbf ft), making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing.

Special Tools The special tools are listed below. It is strongly recommended that the special tools detailed in this procedure are used to ensure correct spacer selection and to prevent repeated dismantling/assembly and a risk of damage to the bearing.

J

Note: The torque of approximately 50 Nm is given as a guide for tightening adapter C. To allow use of rolling torque meter, remove adapter and fit nut 22.

G

A

D Item A D G H J

Part No. 921/52627 997/11000 993/70111 921/52628 892/00918

A270851 A270853

6

If the pinion is not free to rotate or there is no end float at this stage check the bearing is fitted correctly. Also check the correct size spacer has been fitted.

7

Fit special bracket D to the drive-head housing using two M10 x 30 nuts and bolts. Fit special tool support pillar E to bracket D so that the fork end engages in adapter C. Ensure that fork E is centrally located on adapter C. If necessary, re-align bracket D to suit.

Description Spacer 14.20 Drive head setting bracket Break-back torque wrench Spacer kit Setting tool kit

161871

9803/3630

Issue 1


Section F


45 - 11


45 - 11

Fitting a New Spacer to Drive Head (continued) Installation of a Solid Spacer (continued) 8

Fit dial test indicator (DTI) F. Ensure that the DTI is mounted on the drive head and not on bracket D.

9

Set torque wrench G to 35 Nm (25.8 lbf ft) and measure the end float whilst rotating the shaft.

10

To select the right size spacer 30, subtract the end float obtained at step 8 from the solid spacer size (14.20 mm A). Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load. The result is the size of spacer to be fitted from the spacer parts list H. If there is no spacer of this size, fit the next nearest size spacer. Example Temporary spacer size 14.20 Subtract end-float 0.25 Total 13.95 Subtract tolerance & preload 0.04 Result 13.91 (No spacer available this size, use next nearest size spacer i.e 13.900)

Note: To maintain a complete kit, order the relevant spacer after it has been used. 11

Remove sleeve B and spacer A, fit correct size spacer from spacer kit H. During removal take care to avoid damaging the outer bearing.

12

Fit sleeve B. Tighten adapter C to no more than 50 Nm (36.9 lbf ft) to protect against bearing damage while spacer selection is verified making sure the pinion is free to rotate. (See Note following step 5). Check there is no end float and pinion is free to turn smoothly by hand. Remove adapter C and fit nut 22. Then check that rolling torque is less than 2.0 Nm (1.5 lbf ft). If the rolling torque exceeds 2.0 Nm, check that the shaft has been assembled correctly. If the pinion is not free to rotate check the correct size spacer has been fitted.

13

If rolling torque measured at step 12 is too high, fit the next larger size spacer. If rolling torque is too low, fit the next smallest size spacer. If a correct spacer is not available from the range, check that drive head is assembled correctly.

14

Remove adapter C and sleeve B. Fit new oil seal 25, grease between seal lips before fitting. Fit coupling yoke 23 and NEW retaining nut 22.

15

Progressively torque tighten retaining nut 22, occassionally rotating coupling yoke, up to 300 Nm (221 lbf ft). Providing the correct size spacer has been selected the rolling torque should be between 0.5 and 3.5 Nm (0.37 and 2.6 lbf ft) including seal drag.

Note: The nut tightening torque can be increased to a maximum of 390 Nm (287 lbf ft) provided that the pinion rolling torque does not exceed the maximum of 3.4 Nm (2.5 lbf ft). 16

Finally stake the nut 22 into the slot.

Installation of a Collapsible Spacer 1

Smear output shaft inner bearing 28 with JCB HP Grease before refitting. Fit a new collapsible spacer 30 over pinion shaft 31; assemble into drive head casing.

2

Fit spacer 30, after smearing with JCB HP Grease fit outer bearing 26/27 followed by a new oil seal 25. Grease between seal lips before fitting. Assemble yoke 23 and NEW retaining nut 22 with integral washer.

3

Tighten retaining nut to achieve a rolling torque of 1.5 to 2.8 Nm (1.1 to 1.8 lbf ft), in clusive of seal drag.

Note: If this figure is accidentally exceeded, the output shaft must be dismantled and the collapsible spacer 28 renewed. 4

Finally stake the nut 22 into the slot.

G F

E C D

B

348030

9803/3630

348040

Issue 1


Section G

www.WorkshopManuals.co.uk Brakes

i

www.maskinisten.net Section G

i

Contents Technical Data

Page No. 1-1

* Service Brakes

- Dismantling and Assembly Parking Brake Testing Machines up to S/N 772032 - Adjustment - Dismantling and Assembly Machines from S/N 772033 - Lever Adjustment - Cable Adjustment Brake Caliper - Removal - Pad Removal - Inspection - Replacement - Dismantling - Inspection - Assembling - Torque Figures

2-1

3-1 3-2 3-3 3-4 3-5 3-6 3-6 3-6 3-7 3-9 3-9 3 -10 3 - 11

Bleeding

4-1

Fault Finding

5-1

Brake Piston Seal Leakage

5-4

Master Cylinder - Removal and Replacement

6-1

Servo Unit - Removal and Replacement

7-1

Axle Breathers

8-1

9803/3630

Issue 5*


Section G


1-1


Technical Data

1-1

* Service Brakes Type Actuation

Location

Single Circuit, Oil-Immersed Multi-Plate Disc 530 - Hydraulic 533, 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - Hydraulic, servo assisted All Machines - Front Axle Centre Mounted (2 Brake Packs)

Master Cylinder Type

Stroke

530 - master cylinder 533, 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - master cylinder with remote servo unit 530 - 35 mm (1.38 in) 533, 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 25 mm (1.0 in)

Servo Unit Type Vacuum cylinder diameter Hydraulic cylinder diameter

Vacuum assisted hydraulic valve 533, 535, 540 - 135.5 mm (5.33 in) 533, 535, 540, 530FS Super, 540FS Super, 530 SXL, 540 SXL - 19 mm (0.75 in)

General Description The service brakes act on the front axle half shafts of all machines. The brakes are oil immersed, multi-disc types which are operated hydraulically by a single pedal and master cylinder arrangement. All brakes with the exception of 530 machines, are servo assisted. An exhauster (vacuum) unit is fitted on the engine to power the servo unit. The brake cylinder reservoir is situated in front of the instrument panel in the cab. With 2-wheel drive selected, pressing the brake pedal will automatically select 4-wheel drive. This gives increased braking effect. The transmission will switch back to 2-wheel drive when the brake pedal is released. The cable operated parking brake acts on a disc which is mounted on the gearbox output shaft to the front axle.

9803/3630

Issue 5*


Section G



Service Brakes

2-1

2-1

Service Brakes - Dismantling and Assembly The service brakes are located in the front axle, as shown at A. Instructions for dismantling and assembly of the brake are shown in the Transmission section (Front Axle Brakes).

A

A264180

9803/3630

Issue 1




www.maskinisten.net

Section G



Parking Brake

3-1

3-1 *

Testing ! WARNING

SAFETY NOTICE: Ensure all routine health and safety precautions are observed before operating machines.

Do not use a machine with a faulty parking brake. 3-2-3-10

! WARNING

! CAUTION

Before testing the parking brake make sure the area around the machine is clear of people.

Non approved modifications to axle ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.

2-2-4-5

1

Enter the machine. Fasten your seat belt (if fitted) and park the machine on a level dry surface.

2

Fully apply parking brake 1.

3

Start the engine and raise the attachments to the appropriate travelling position.

4

Select fourth gear 2.

5

Push down hard on foot brake pedal 3.

6

Select forward drive 2.

3-2-3-11

*

4

2

! WARNING If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed. 2-2-5-1

Test the parking brake as follows: 7

1 3

Move the parking brake lever fractionally forward until the warning light 4 is just extinguished.

8

Slowly release the foot brake pedal 3.

9

If the machine has not moved, use the accelerator to gradually increase the engine speed to approximately 1500 RPM. The machine should not move.

10

Do not do this test for longer than 20 seconds.

11

Reduce engine speed to idle and select neutral 2.

12

Return park brake lever 1 to the fully on position from its partially applied position.

13

Lower attachments and stop the engine.

14

If the machine moved during the test, adjust the parking brake and repeat the test. Be sure to use the correct adjustment procedure for the applicable machine - see Contents.

9803/3630

S263240

Issue 2*


Section G



Parking Brake

3-2

3-2

Machines up to S/N 772032 Adjustment

! 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.

Measure the pad thickness. If the friction material Ais 3 mm (0.125 in) or less, always fit a new set of pads. Check that the pads just touch the disc, shown at B, with the parking brake disengaged (lever horizontal).

Whenever the parking brake has been used in an emergency, always renew both brake pads.

If necessary, adjust the pad position by turning nut C. Turn the nut clockwise to close the pads onto the disc.

4-2-1-1/2

! WARNING * Before working on the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you. 2-3-2-4/1

The parking brake should be fully engaged when the lever is vertical. The parking brake indicator light should light when the brake is engaged with the forward/reverse lever away from neutral (starter switch at IGN).

Check and Adjust the Pad Position

2

Take Up the Cable Slack a Disengage the parking brake (lever horizontal). b Turn handle grip D clockwise, half a turn. c Test the parking brake, see Parking Brake Testing, this section. * 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

A D C

350020

S260240

B

327060

9803/3630

Issue 4*


Section G



Parking Brake

3 - 2A

3 - 2A

Renewing the Brake Pads *1

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 caliper 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 calipers 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 (4.4 lbf ft).

12

Engage spring in brake calipers and tighten bolts so that the calipers move freely (14Nm, 10.3lbf 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 parking brake, see Parking Brake - Testing, this section.

2

5 5

8

7

9

6

8

4 9

3 9

12 14Nm (10.3lbf ft) 12 993/2360 452/0270

12

10 11

14

14 15/92016

11 6Nm (4.4lbf ft)

15/92015

13

9803/3630

Issue 2*




www.maskinisten.net

Section G



Parking Brake

3-3

3-3 *

Machines up to S/N 772032 (cont’d) Lightly grease all pivots and working surfaces, taking care not to allow grease to contact the brake pads.

Dismantling The numerical sequence on the illustration is intended as a guide to dismantling. For assembly, reverse the sequence.

Tighten nut 5 sufficiently to allow lever 7 to move freely with minimum side clearance.

Assembly *

Torque Settings Note: Apply JCB Threadlocker and Sealer to mounting bolts 1 before fitting.

Item 1

Nm 118

kgf m 12.0

lbf ft 87

Fit shims A as necessary to align the caliper 2 centreline to within ± 0.5 mm (0.020 in) of the brake disc centreline.

10

20

2.0

15

15

6

0.6

4.4

S120160

9803/3630

Issue 2*


Section G



Parking Brake

3-4

3-4

Machines From Serial Number 772033 Lever Adjustment The parking brake must be fully engaged when the lever is vertical. The parking brake indicator light must illuminate when the brake is engaged with the forward/reverse lever away from neutral (starter switch at IGN). Later machines may be fitted with alternative parkbrake lever B. Squeeze the release lever under the hand grip and lower the parking brake forward to release. 1

Test the parking brake. See Testing (this section). Adjust the parking brake as described below if the machine moved during the test.

2

Release the parking brake (lever horizontal).

3

Turn hand grip A or B half a turn in the direction shown and re-test the brake.

4

If the brake fails the test, repeat Steps 2 and 3.

If there is insufficient adjustment using the parking brake lever, see Cable Adjustment.

A

B

A349070 A347580

9803/3630

Issue 2*


Section G



Parking Brake

3-5

3-5 Cable Adjustment

! 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.

A

BRAK 8-8

Renew the cable and check the pad thickness if adjusting nuts are not fitted. See Brake Caliper. Always renew a worn or damaged cable.

A349070

1

Disengage the parking brake (lever horizontal).

2

Turn hand grip in direction shown to centre pin A in its slot. If the later type park brake lever is fitted: (a) (b) (c)

3

4

Release the parking brake. Fully adjust the hand grip. Turn the hand grip in the direction shown to position the mechanism at the centre of its adjustment (approximately 15 turns from the fully adjusted position).

Release the two locknuts at B and adjust the cable length as required. Renew both brake pads if there is insufficient adjustment at the cable. Renew the cable if there is still insufficient adjustment after new pads have been fitted.

A347580

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. Note: If a new cable is fitted, position the threaded section of the cable with approximately four threads visible below the bottom adjusting nut.

5

Test the parking brake. Make final adjustments at the park brake lever if the brake fails the test. See Lever Adjustment.

C B

A348100

9803/3630

A326153

Issue 2*


Section G



Parking Brake

3-6

3-6

Brake Caliper ! WARNING

C

Installation and mounting of the parking brake caliper 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

A

B

This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

C

! WARNING

D

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

A326153

Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper before commencing work. Clean hands thoroughly after work. 13-3-1-3

Inspection

Removal 1 2

Note which hole in the operating lever clevis A is attached to and disconnect the clevis.

3

Remove clip B and disconnect the cable from the bracket.

4

! WARNING

Release the parking brake lever (lever horizontal).

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

Support the caliper and remove the two mounting bolts and hardened washers C. Lift the caliper clear of the brake disc.

1

Check the thickness of the friction material on the two brake pads. Renew both brake pads if the thickness of friction material is below 1mm (0.04 in) on either pad.

Note: Do not remove transmission mounting bracket D unless it needs to be renewed.

2

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn.

Pad Removal

3

Renew the cable if worn or damaged.

See Dismantling (Page G/3-8) 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 side 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.

9803/3630

Issue 2*


Section G 3-7



Parking Brake

3-7

Replacement

B

Replacement is the reverse of removal. See Dismantling (Page G/3-8) for parts identification. 1

If transmission mounting plate D has been removed, secure in place using three new verbus rip bolts. These bolts can only be used once. See Torque Figures.

C

E

C

If the mounting plate has not been removed, check the retaining bolts are tightened as above before proceeding further.

D

Later machines are fitted with an improved transmission mounting plate which cannot be removed with the brake disc in place. See Torque Figures. 2

Fit lever side pad 2. Position the pad on the face of the rotor 9 and carefully press in place on the plastic clip in the centre of the rotor.

3

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.

4

Replace the caliper. Fit new mounting bolts C with hardened washers and tighten to 255 Nm (188 lbf ft).

5

Make sure floating parts move freely and that all other parts are mounted securely. Tighten all mounting bolts to the recommended torque figures. See Torque Figures.

6

Attach the cable to the mounting bracket and secure in place with clip B.

7

Refit the clevis to the relevant hole in the operating lever as follows:

A326153

Torque Settings Item C

Nm 255

lbf ft 188

TOP HOLE - Attach the cable to the top hole of the operating lever only if the cable is fitted with adjusting nuts under the cab. MIDDLE HOLE - Attach the cable to the middle hole of the operating lever if the cable is not fitted with adjusting nuts under the cab. 8

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.

9

Adjust the parking brake (see Lever Adjustment and Cable Adjustment). Never unscrew the clevis to adjust the cable.

9803/3630

Issue 2*


Section G



Parking Brake

3-8

8

14

15

13 13

12

13

13

12

11

10

2

9

1

3-8

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

9803/3630

Issue 1


Section G



Parking Brake

3-9

3-9 Dismantling

Inspection

The numerical sequence shown on the illustration is intended as a guide to dismantling.

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 and 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 caliper 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 Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper before commencing work. Clean hands thoroughly after work. 13-3-1-3

1

Remove the caliper and brake pads. See Caliper 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.

9803/3630

Issue 1


Section G

www.WorkshopManuals.co.uk Brakes Parking Brake

3 - 10


3 - 10

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. Insert ball spacer 10.

4

Slide rotor 9 through the housing 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. The correct position of the lever is 15° clockwise from the vertical position as shown.

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 on the anti-rotation clip that aligns with one of the flats on the bolt.

15˚

Y

X

A348330

10 Fit the new brake pads. See Caliper - 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 caliper, 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 caliper. See Caliper - Replacement.

14

Adjust the parking brake. See Lever Adjustment and Cable Adjustment.

Torque Settings Item 3

Nm 13-16

lbf ft 9-12

9803/3630

Issue 1


Section G

www.WorkshopManuals.co.uk Brakes Parking Brake

3 - 11


3 - 11

Torque Figures 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. Note: Later transmission casings are fitted with improved mounting bracket A. Make sure the bolts securing the bracket are tightened to the correct torque figure shown below.

A Transmission Mounting Bracket Bolts Verbus Ripp (12.9) 8 off Powershift 7 off Syncro Shuttle 166Nm (122 lbf ft) Always fit new bolts

Caliper Mounting Bolts (10.9) Tuflok Bolt 255 Nm (188 lbf ft)

Hardened Washer

Transmission Mounting Bracket Bolts Verbus Ripp 85Nm (63 lbf ft) Always fit new bolts

Spindle Bolt 13-16 Nm (9-12 lbf ft)

9803/3630

A348820

Issue 1


Section G



Bleeding

4-1

4-1

A

C

S107710

Front Axle

A

A311810

*

9803/3630

Issue 6*


Section G



Bleeding

4-2

4-2

! 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

Fill the reservoir with correct fluid (see Lubricants and Capacities, Section 3) and ensure that throughout the bleeding procedure the level is not allowed to fall below the MINIMUM mark.

! WARNING Use of incorrect fluid will cause serious damage to the seals which could in turn cause brake failure. Brake 1-1

Attach a tube to the appropriate bleed screw, ensuring that the free end of the tube is immersed in fluid in a suitable container. Open the bleed screw and apply one rapid full stroke of the brake pedal followed by three rapid short strokes from the halfway pedal position. After the third short stroke, allow the pedal to return quickly to its stop. Continue bleeding normally until all air is dispelled, closing the bleed screw with the pedal fully depressed. Bleed the brake system, in the appropriate sequence, as follows: * 530 Machines without servo brakes Bleed at point C on the front axle. Machines with servo brakes Bleed in turn at point A on the servo unit and point C on the front axle. Top up reservoir to the full mark.

9803/3630

Issue 5*


Section G



Fault Finding

5-1

5-1

Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal.

FAULT

POSSIBLE CAUSE

ACTION

A

1

Master cylinder fault.

1

Check master cylinder to identify fault area, service as required.

2

Friction/counter plate distortion.

2

Renew friction/counter plates BOTH sides of relevant axle.

1

Air in hydraulic system.

1

Check fluid reservoir level. Check for fluid/air leaks, rectify as required. Bleed the brake system.

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. Top up brake reservoir and bleed the brake system.

3


3

See Item A2.

1

Tightness at pedal pivot.

1

Inspect pedal pivot. Free-off/ lubricate.

2

Fluid contamination/seal damage.

2

Flush system and renew all hydraulic seals. Bleed the brake system.

3

Misaligned push rod/pedal.

3


4

Kinked or crushed brake pipes.

4

Check/renew brake pipework.

B

C

One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side.)

Pedal travel excessive (but not touching floor.)

Pedal hard to operate.

Items 5 to 7 are for machines fitted with servo assisted brakes only (i.e. all except 530 models).

D

E

Pedals touch floor under constant pressure - no fluid loss.

Pedal touches floor under constant pressure - and fluid loss.

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

See Item A1.

2


2

See Item A2.

3

Air in hydraulic system.

3

See Item B1.

1

External fluid leaks.

1

Visually check brake circuit for fluid loss, service as required. Top up brake reservoir and bleed the brake system.

2

Internal fluid leaks.

2

See Brake Piston Seal Leakage.

9803/3630

Issue 1


Section G



Fault Finding

5-2

5-2 FAULT

POSSIBLE CAUSE

ACTION

F

1

Friction plates worn beyond limits or distorted.

1

Renew friction/counter plates - BOTH sides of relevant axle.

2


2

See Item A1.

3

Annular piston fault.

3

See Item G6.

4

Incorrect/low axle oil.

4

Fill axle with correct type of oil.

5

Vacuum failure (machines fitted with servo assisted brakes, i.e. all except 530 models).

5

Inspect vacuum source/pipes, service as required.

1

Brake pedal spring fault.

1

Fit a new spring.

2

Master cylinder fault (plunger stuck in bore).

2

See item 1A.

3

Blocked hole in master cylinder reservoir cap.

3

Fit a new reservoir cap.

4

Brake pedal free travel incorrect.

4

Adjust pedal free travel.

5

Fluid contamination/seal damage.

5

Flush system and renew hydraulic seals. Refill with clean fluid and bleed the brake system.

6

Annular brake piston(s) binding in axle.

6.1 Check that correct brake fluid has been used (incorrect fluid could swell the annular brake piston seals). 6.2 Check if annular brake piston seals in good condition. 6.3 Check that annular brake piston rotates freely in its housing with no seals fitted. 6.4 Check that the annular brake piston seal retracts the piston approximately 0.5 mm (0.020 in).

7

Kinked or crushed brake pipes.

7

Check and renew pipes as required.

8

Friction/counter plates not free on splines and/or dowels.

8

Check friction/counter plates for free movement, renew if required - BOTH sides of relevant axle.

1

Moisture in system vapourising when axle is hot.

1

Strip axle and clean annular piston to remove moisture. Remove master cylinder and check for corrosion, service as required. Flush system refill with clean fluid. Bleed the brake system.

G

H

Poor braking (not pulling to one side).

Brakes not releasing.

Poor braking when hot.

and

9803/3630

Issue 1


Section G



Fault Finding

5-3

5-3 FAULT J

POSSIBLE CAUSE

Excessive brake noise in operation. 1

Deterioration of axle oil or wrong type of axle oil.

1

Change axle oil.

Axe oil loss.

2

Refill axle with correct oil and check for leaks.

Friction plates worn beyond limits.

3

Renew friction/counter plates - BOTH sides of relevant axle.

4

Friction/counter plates in poor condition.

4

Check for distortion or surface pitting and/or roughness of friction/counter plates (annular grooving of counter plates is acceptable).

1

Severe damage or slight cut/nick in the brake piston seal.

1

Check as described under Brake Piston Seal Leakage on the following pages. If necessary, strip axle and renew seal(s).

2

External leakage through brake pipe connections, etc.

2

Check for and repair leaking connections.

Note: Due to the metal to metal contact of oil immersed brakes, limited noise can 2 be heard which is consistent with this type of design - this is normal. 3

K

Fluid loss when machine standing for instance - overnight (see Note). Note: Confirm fault is as indicated by checking that the brake pedal DOES NOT touch the floor under constant pressure.

ACTION

9803/3630

Issue 1




www.maskinisten.net

Section G



Fault Finding

5-4

5-4

*

F C A E

D

F C G

E B

D

A335610

9803/3630

Issue 2*


Section G



Fault Finding

5-5

c

Using a suitable pen, mark the level line of the brake fluid on the tube, as shown at G.

5-5

Brake Piston Seal Leakage The most common reason for internal piston seal leakage is a build-up of axle contamination as a result of excessive brake wear caused by extended service periods.

d After approximately 1/2 hour, check if the level has dropped below the original marked line. If it has, check the brake piston seal for slight nicks, cuts or generally for wear.

Note: An overfull hub is an indication of a possible brake seal leak. If this is confirmed change the axle/hub oil after renewing the seal(s). Two types of internal leakage can occur within the axle or hub:

e 5

Repeat steps a to d at port F.

Test for a High Pressure Leak: a

Install a hand pump fitted with a 0 - 40 bar (0 - 600 lbf/in 2) pressure gauge (as shown at X) to brake piston port E.

a

Low Pressure Leaks - Seal damage, or scoring to seal component surfaces, caused by a build-up of metal particles.

b

High Pressure Leaks - Mechanical leakage past a badly damaged or perished seal.

Note: The hand pump MUST be filled with JCB Light Hydraulic Fluid. DO NOT exceed 69 bar (1000 lbf/in2).

Note: The low pressure leak test should be performed first. Low pressure leaks are difficult to find using a high pressure test - seals and other components can distort and form a seal under pressure.

b Use the hand pump to generate a pressure in the brake piston housing. c

The following procedures explain how to check for low or high pressure leaks without the need to dismantle the axle first. The test must only be done when the axle is COLD.

d Repeat steps a to c at port F. 6

* Front Axle

! WARNING

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.

Re-instate the Brake System: Reconnect all brake pipes and bleed the brake system (see Bleeding) or proceed to rear axle, if appropriate.

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

Preparation 1

Disconnect and cap brake piston feed pipe A (non-sway machines) or feed hose B (sway machines).

2

Completely remove pipe C and plug port D.

3

Fill both brake piston housings with JCB Light Hydraulic Fluid via ports E and F.

4

Test for a Low Pressure Leak: a

Install an adapter fitted with a piece of clear tube (as shown at Y) to the brake piston port E.

Note: The tube must be kept vertical during the test, use tape to attach the tube to the side of the machine. b Fill the tube until approximately three quarters full with JCB Light Hydraulic Fluid.

9803/3630

Issue 2*


Section G



Master Cylinder

6-1

6-1

C B

A

A D

D

D D

D

A311800

530 Machines

* 533, 535, 540 Machines

9803/3630

Issue 3*


Section G


www.maskinisten.net section G

Master Cylinder

6-2

6-2 * Removal 1

Remove clevis pin A to disconnect the master cylinder operating rod from the brake pedal mechanism.

2

Disconnect plastic feed pipe B from the brake fluid reservoir and either blank off the pipe or drain the reservoir.

3

Disconnect the master cylinder output hose C. Plug the cylinder port and blank off the hose (or pipe) to prevent ingress of dirt.

4

Remove screws D and lift the master cylinder clear of the machine.

Note: The master cylinder is not serviceable and must be renewed if faulty.

Replacement Replacement is the reverse of Removal. Once the master cylinder is installed and the pipework connected check the brake fluid reservoir (see Checking the Brake Fluid Level, Section 3) and then bleed the brake system (see Bleeding).

9803/3630

Issue 2*


Section G



Servo Unit

7-1

7-1

Removal 1

Disconnect servo vacuum hose A.

2

Disconnect and blank off master cylinder output pipe B. Plug the cylinder port.

3

Disconnect cylinder output hose D. Blank off the hose and plug the cylinder port.

4

Loosen the three securing nuts F and slide the servo unit out of its mounting bracket.

F A B

Replacement

F

Replacement is the reverse of Removal. Once the servo unit is installed and the pipework connected, check the brake fluid reservoir (see Checking the Brake Fluid Level, Section 3) and then bleed the brake system (see Bleeding).

D F A311820

* 533, 535, 540 Machines

9803/3630

Issue 3*


Section G

www.WorkshopManuals.co.uk Brakes Axle

8-1


8-1

Axle Breather (Braked Axles) Breathers are fitted to axles to relieve pressure build up, due to braking and prolonged roading.

A

If breathers are not kept clear, seal leakage and brake problems can result due to pressure build up. Most axles are fitted with long stem breather Type A.

C

Outboard Brakes Ensure there is adequate clearance around the breather and if it should be dislodged or removed, ensure it is refitted with Hole C pointing outwards towards the wheel. The breather is always fitted on the opposite side to the crownwheel (in less turbulent oil) avoiding oil seepage. Plug B is fitted in the crownwheel side.

B

9803/3630

Issue 1




www.maskinisten.net

Section H

www.WorkshopManuals.co.uk Steering

i

www.maskinisten.net Section H

i * Contents

Page No.

Special Tools

1-1

Technical Data System Type Pump Steering Valve

1-2 1-2 1-2

Basic System Operation Hydraulic Operation Hydraulic Component Location Electrical Component and Connector Location Electrical Operation

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

Electrical Connections

3-1

Circuit Description Steer Unit Operation Machines to Serial No. TBA Machines from Serial No. TBA Priority Valve Operation System Operation - 2-Wheel Steering - 4-Wheel Steering - Crab Steering Fault Finding Contents Introduction Mechanical/Hydraulic 4WS Phasing Faulty Electrical Servicing Procedures System Bleeding Checking the Steering Pressure Adjusting the Steering Pressure Priority Valve - Cleaning - Standby Pressure Testing

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

8-1 8-1 8-1 8-4 8-5

9-1 10 - 1 10 - 1 11 - 1 11 - 1

Power Track Rods

Removal Replacement Link Arms Dismantling and Assembly

12 - 1 12 - 1 13 - 1 14 - 1

Priority Valve Removal Replacement Dismantling and Assembly

20 - 1 20 - 1 20 - 1

9803/3630

Issue 5*


Section H


ii


ii

Contents Steer Mode Valve Checking Solenoid Operation Removal Replacement Dismantling and Assembly Hydraulic Steering Unit Removal and Replacement Dismantling and Assembly Machines to Serial No. TBA Machines from Serial No. TBA

Page No. 23 - 1 23 - 1 23 - 1 24 - 1

30 - 1 35 - 1 36 - 2

9803/3630

Issue 1


Section H

www.WorkshopManuals.co.uk Steering Technical Data

1-1 * Special


1-1

Tools

The following special tools are required for procedures detailed in this Section.

892/00180

Seal Fitting Tool for fitting ‘O’ ring and back-up ring to hydraulic steering unit - see Hydraulic Steering Unit, Assembling.

892/00181

Replacement Plastic Boss

S191750

892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) see Checking the Steering Pressure 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) see Priority Valve - Standby Pressure Testing

9803/3630

Issue 4*


Section H

www.WorkshopManuals.co.uk Steering Technical Data

1-2

System Type


1-2

Fully hydraulic load sensing with selectable 2-wheel, 4-wheel and crab steer modes. Anti-cavitation valve on machines to Serial No. 773053. Powered track rod on both axles

Pump

See Section E.

Steering Valve Earlier Machines Displacement Relief Valve Pressure: Shock Relief Valve Pressure:

200cc/rev 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 2 235 bar (239 kgf/cm ; 3407 lbf/in )

Machines from Serial No. TBA Displacement Relief Valve Pressure: Shock Relief Valve Pressure:

95cc/rev (2:1 ratio) 2 2 175 bar (178 kgf/cm ; 2500 lbf/in ) 2 235 bar (239 kgf/cm ; 3407 lbf/in2)

9803/3630

Issue 1


Section H

www.WorkshopManuals.co.uk Steering Basic System Operation

2-1


2-1

D T

B

P

A

E LS P

B

A

R L P

E

LS

C 388591

E D AB E

C

A311952

*

Hydraulic Operation The fully hydraulic steering system is similar for all machines. The hydraulic circuit shown opposite is simplified for the purposes of explanation; for the detailed circuit, refer to the appropriate hydraulic schematic in Section E.

When required, oil from the priority valve is delivered to steer unit C at the bottom of the steering column. Turning the steering wheel operates the steer unit which directs oil to power track rods E on the axles.

Oil is supplied from gear pump A driven by the engine via the bevel gearbox. The pump is fitted with a load sensing, priority valve B which always gives priority to demands from the steering circuit. When there is no demand, it directs oil back to the control valve.

The hydraulic circuit is designed so that the machine can still be steered if the engine fails (although more effort is required).

9803/3630

Issue 4*


Section H 2-2



Basic System Operation * Hydraulic

2-2

Component Location

Key A

Hydraulic Pump Triple Pump S Suction port, from hydraulic tank T Tank port, return to hydraulic tank V Valve port, to main control valve Double Pump S Suction port, from hydraulic tank T Tank port, return to hydraulic tank

B

Priority Valve LS Load sensing port, from Steering Unit LS port P Pressure port, to Steering Unit P port Triple pump EF Secondary port, to hydraulic tank Double pump EF Secondary port, to main control valve

C

Steering Unit R Right port, to Steering Mode Valve T port L Left port, to front power track rod left hand end LS Load sensing port, to Priority Valve LS port P Pressure port, to Priority Valve P port To s/n 773053 T Tank port, to Steering Mode Valve C port From s/n 773054 T Tank port, to hydraulic tank, via adapter, see Steer Unit Operation

D

Steering Mode Valve A A port, to rear power track rod right hand end B B port, to rear power track rod left hand end P Pressure port, to front power track rod right hand end T Tank port, to Steering Unit R port To s/n 773053 C C port, to Steering Unit T port V V port, return to hydraulic tank From s/n 773054 C Not used V Not used

E1

Power Track Rod (front) 1 Hose to Steering Unit L port 2 Hose to Steering Mode Valve P port

E2

Power Track Rod (rear) 1 Hose to Steering Mode Valve B port 2 Hose to Steering Mode Valve A port

9803/3630

Issue 4*


Section H 2-3

Steering



Basic System Operation

2-3 2

D

E2

P

V

C

1 T

A B

Triple pump to S/N 771428

A

S LS P

T

V

B

EF

Triple pump from S/N 771429

S

EF

P

2

E1

A311953

1

C

LS

B

T

V

T

Double pump L

EF

S

LS P LS

P R

V

B Issue 1

9803/3630


Section H


Steering


2-4

Basic System Operation

2-4

M

D2

D

L1

L3

L2

C9

C10

C19

H

C20

D1

C14

C13

C11 D3

D4

C15

C16

A292782

C12

309100

390110

C1

L

C5

J C3

C6

C2

C4

390070 388671

G

C21

K

C22

FB1 7.5 10 5 15 15 15 2.5 7.5 10 7.5

FB2 5 7.5 10 5 10 10 7.5 7.5 7.5

A388531

C7 C8

388650

Issue 1

9803/3630


Section H


2-5


2-5

Electrical Component and Connector Location Key D

Steering Mode Valve C13 Connection to 2WS solenoid, part of chassis harness C14 Connection to AWS solenoid, part of chassis harness C15 Connection to 4WS solenoid, part of chassis harness C16 Connection to crab solenoid, part of chassis harness D1 2WS solenoid D2 AWS solenoid D3 4WS solenoid D4 Crab solenoid

G

Steering Sensor (front) C21 Part of chassis harness C22 To proximity switch

H

Steering Sensor (rear) C19 Part of chassis harness C20 To proximity switch

J

Steer Mode Switch C5 Part of panel harness C6 To steer mode switch

K

Steer Mode Control Unit and Fuse Blocks C7 Part of panel harness C8 To steer mode control unit FB1 Fuse block 1 FB2 Fuse block 2

L

Bulkhead Connectors C1 Bulkhead connector, part of panel harness C2 Part of chassis harness C3 Bulkhead connector, part of panel harness C4 Part of chassis harness

M

Instrument Panel C9 Part of panel harness C10 Instrument panel connector C11 Part of panel harness C12 Instrument panel connector L1 4 wheel steer indicator light L2 2 wheel steer indicator light L3 Crab steer indicator light

9803/3630

Issue 1


Section H


2-6


2-6

K

J L1

H

L2

D

L3

G F13 F8

H

M J D

K G

A388531

Electrical Operation Three steering modes are available: -

Two-wheel steer (front) Four-wheel steer Crab steer

The three modes are selected in the cab from a three position switch J which operates relays in the steer mode control unit K. The relays switch the energising supplies to the solenoid operated steer mode valve D. Proximity switches on the front G and rear H axles signal when the wheels are in the straight ahead position. Lights L1, L2 or L3 on the instrument panel M illuminate to indicate the steer mode currently operative.

In 2-wheel steer mode only the front wheels are steered. In 4-wheel steer mode both axles are steered, giving a smaller turning circle and so improving manoeuvrability. The crab steer mode allows the machine to be driven diagonally into loading/unloading positions which might otherwise be inaccessible. The system is prevented from changing mode until the relevant proximity switch is energised. If, for example, the system is set in 4-wheel steer and 2-wheel steer is selected, the system will stay in 4-wheel steer until the rear wheels are turned to the straight ahead position, thus energising the rear axle proximity switch. The rear wheels are then hydraulically locked in the straight ahead position. Refer to the Circuit Description, System Operation pages for full details of proximity switch functions in different modes.

9803/3630

Issue 1




www.maskinisten.net

Section H 3-1

www.WorkshopManuals.co.uk Steering * Electrical

On the electrical connection diagram opposite, the matching pairs of connectors (C1 to C22) are shown looking on the mating face of each connector when they are disconnected. The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding. The numbers correspond to the numbers on the electrical schematic (see Harness and Wire Number Identification in Section E).


Connections

3-1

Component Key D1 D2 D3 D4 EBE FB1-8 FB2-13 FL1 FL2 IP IS L1 L2 L3 G H J K WB

Steer mode valve - 2WS solenoid Steer mode valve - AWS solenoid Steer mode valve - 4WS solenoid Steer mode valve - crab steer solenoid Engine block earths Fuse 8 on fuse block 1 Fuse 13 on fuse block 2 From fusible link 1 via ignition relay Fusible link 2 Instrument panel warning light cluster Ignition switch (viewed from rear) ‘4WS selected’ indicator light ‘Crab steer selected’ indicator light ‘2WS selected’ indicator light Front axle proximity switch Rear axle proximity switch Steer mode selector switch Steer mode electrical control unit Warning buzzer

9803/3630

Issue 3*



Steering

Section H

* Electrical

3-2

Section Hwww.maskinisten.net

Connections

3-2

EBE

C23

C22

C24

C19

C21

IP

G L1 L2 L3

C2

C14 C15

C13

C9

C12

D1

D2

C20

H

C16

D3

D4

C10

C1

C11

IS FL2 (40A) FL1 601W

WB

J

C4

C3 C6

C5

K

FB2-13

C8

FB1-8

C7 A318871

9803/3630

Issue 3*




www.maskinisten.net

Section H

www.WorkshopManuals.co.uk Steering Circuit Description

4-1


4-1

Steer Unit Operation Machines to Serial No. TBA

3

Note 1: The schematic shows priority valve 1A in the position it adopts during a turning operation. Its ‘neutral’ position is shown under Priority Valve Operation, Neutral. Note 2: Port EF is connected to the control valve block 4.

3A

Neutral Whenever the steering wheel is stationary, irrespective of the position of the steered road wheels, steer unit 2 adopts the neutral position. The inner spool and sleeve are held in neutral by the centring springs. As the steer unit is ‘closed centre’ the flow from the pump is dead-ended by the unit. This is sensed by the steering priority valve (see Priority Valve Operation, Neutral for full details).

2 3A

Turning

Y

2B

2

Z

2A

Turning the steering wheel moves the inner spool a few degrees relative to the outer sleeve. This sends a pressure signal to relief valve 2B and, through the LS port, back to priority valve 1A which adopts the position shown on the schematic. Flow from priority valve 1A in main hydraulic pump 1 enters steer unit 2 via port P and non-return valve 2A. The relative movement between the inner spool and outer sleeve directs pressure oil through 6 of the 12 holes in the bottom of the outer sleeve. The metering unit is linked to the inner spool and outer sleeve by a cross pin. As the steering is operated the oil is diverted by the inner spool to the stator. The rotor lobes pump the oil out via steer mode valve 3 to the appropriate steering ram(s) and the required degree of turn is executed.

4 1

1A

During a steering operation, oil returns to tank as follows: On Machines to S/N 773053 - via steer unit 2 and anti-cavitation valve 3A as shown on the main illustration.

T

A343400

On Subsequent Builds - directly via steer unit 2. Note that the hoses previously connected to steer mode valve 3, ports C and V, are now connected together via adaptor Y. (Refer to Steer Mode Valve, Removal and Replacement for full details). When the ram(s) reach full stroke, the pump flow is dead ended, a higher pressure signal is felt at relief valve 2B which opens to route excess oil back to tank or to the control valve, as appropriate.

9803/3630

Issue 1


Section H


4-2

T


4-2

3

B

5

4

P

2

L

A

R

2C

2A

LS

2B P

2D T

LS

P

1

EF

1A 1C 1B

16

36

T

416510

9803/3630

Issue 1


Section H



Circuit Description

4-3

4-3

Steer Unit Operation Machines from Serial No. TBA Note 1: The schematic opposite shows priority valve 1A in the position it adopts during a turning operation. Its ‘neutral’ position is shown under Priority Valve Operation, Neutral.

A

L

R

2

Note 2: Port EF is connected to the two spool valve block to provide lift end services. Neutral Whenever the steering wheel is stationary, irrespective of the position of the steered road wheels, steer unit 2 adopts the neutral position as shown in the schematic opposite. The spool is held in neutral by the centring springs. As the steer unit is ‘closed centre’ the flow from the pump is dead-ended by the unit. This is sensed by the steering priority valve (see Priority Valve Operation, Neutral for full details).

LS

Turning Turning the steering wheel to the left moves the spool to the position shown at A. This sends a pressure signal to relief valve 2A and, through the LS port, back to priority valve 1A which adopts the position shown on the schematic. Flow from priority valve 1A in main hydraulic pump 1 enters steer unit 2 via port P and non-return valve 2B. With the spool in the position shown at A, pressurised oil is directed through the steer unit, leaving by port L to the front steering rams. Displaced oil from the rams is returned via steer mode valve 3 to port R, through the valve spool as shown, exiting via port T.

2A T

B

2B P

L

388580

R

2

Turning the steering wheel to the right moves the spool to the position shown at B. This operates priority valve 1A in the same way as that described above, flow from the main hydraulic pump 1 again entering steer unit 2 via port P and non-return valve 2B. With the spool in the position shown at B, pressurised oil is directed through the steer unit, leaving by port R to the front steering rams. Displaced oil from the rams is returned via steer mode valve 3 to port L, through the valve spool as shown, exiting via port T. In either case, the increased pressure felt at the front right hand ram causes anti-cavitation valve 3A to open, allowing the flow from port T to return to tank. Should the ram tend to cavitate, this pressure is lost and valve 3A closes, dead ending the return flow and preventing cavitation occuring.

LS 2A

2B T

P

388570

When the ram(s) reach full stroke, the pump flow is dead ended, a higher pressure signal is felt at relief valve 2B which opens to route excess oil back to tank.

9803/3630

Issue 1


Section H


5-1


5-1

Priority Valve Operation Neutral Up to machine number 77129, the priority valve is an integral part of the main hydraulic pump; from machine number 77130, the priority valve is mounted on the side of the pump (see Hydraulic Component Location in this section). In both cases, it supplies hydraulic oil to the steer circuit on demand. Note: The illustrations below and opposite are for the purpose of showing the operation of the priority valve only and are not necessarily an accurate pictorial representation of a particular type of priority valve.

When the steering is not being operated, flow to steering circuit is dead ended by the closed centre steering unit 2 and 'no load' is sensed in line LS. Pump outlet pressure at A is fed through orifice B to the priority valve spool C and via orifice D to the underside of the priority spool. Because of the large pressure difference across the priority valve spool C the valve moves up against the spring pressure and all pump outlet pressure is fed via port EF to the tank (triple pump) or to the control valve (double pump). See Hydraulic Pump in Section E.

LS

A B

P

EF

C

D

T

2 A308141

9803/3630

Issue 4*


Section H


5-2 * Priority


5-2

Valve Operation (continued)

Turn As the steering unit 2 is operated, pressure is applied to the spring end of the priority valve spool C via sensing line LS.

When the steering reaches the required position, sensing pressure via port LS ceases, restoring the pressure difference across the priority valve spool C allowing full flow to tank.

The reduced pressure difference across the priority valve spool C causes the spool to move down under spring force. The pump outlet pressure at A flows through port P via the priority valve spool C. The oil then flows to the steer unit 2 and on to the steer rams to turn the wheels in the direction required.

Maximum steering pressure is controlled by the relief valve in the steering unit 2.

The excess oil flows via port EF to the tank (triple pump) ot to the control valve (double pump). See Hydraulic Pump in Section E.

LS

A B

P

EF

C

D

T

2 A313610

9803/3630

Issue 4*


Section H


6-1


6-1

Steer mode control valve D - ports internally connected T→P

335271

9803/3660

Issue 1


Section H


6-2


6-2

K

9 K3

K4

K5

8

K6

10 K2

9 8

K1

10

J

L1 H

L2

L3

D D1

G

D2

D3

D4

F13

F8

System Operation 2-Wheel Steering Electrical Circuit

Hydraulic Circuit

With the rear axle in the straight ahead position and selector switch J in the 2-wheel steer position, current flows from fuse F13 through the rear axle proximity switch H, then selector switch J, to energise relay K5 and move relay switch K2 contacts to the 9/10 position. Current then flows to energise the 2-wheel steer solenoid D4, going to earth through relay switch K2 contacts 9/10. Current also flows from fuse F8 and illuminates the 2-wheel steer warning light L3, going to earth through relay switch K2 contacts 9/10.

With the spools of steer mode control valve D in the 2-wheel steer position there is a hydraulic connection between the steer unit C and the front axle power track rod E1. The oil feed to the rear axle power track rod E2 is blocked by the spool assembly and held in the straight ahead position by the locked-up hydraulic oil in the rams.

If the rear axle is not in the straight ahead position when 2wheel steer is selected the system remains in 4-wheel steer or crab steer mode, until the rear axle is in the straight ahead position when the rear axle proximity switch H is activated. The sequence is then as described in the first paragraph.

When the steering wheel is turned (right turn shown), only the front axle power track rod E1 is operated by the steering unit C. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction. Note: On machines from S/N 773054 anti-cavitation valve D5 is by-passed as shown at inset Z.

9803/3660

Issue 1


Section H


6-3


6-3

Steer mode control valve D - ports internally connected T→A B→P

335281

9803/3660

Issue 1


Section H



Circuit Description

6-4

6-4

K 9 8 K3

K4

K5

10

K6

K2

9 8

10 K1

J

L1

L2

L3

H D D1

G

D2

D3

D4

F13

A172061

F8

System Operation Hydraulic Circuit

4-Wheel Steering Electrical Circuit With the front axle in the straight ahead position and selector switch J in the 4-wheel steer position, current flows from fuse F13 through the front axle proximity switch G, then selector switch J7, to energise relays K3 and K4 and move relay switches K1 and K2 contacts to the 8/9 position. Current then flows to energise the steer solenoids D1 and D2, going to earth through relay switches K1 and K2 via contacts 8/9. Current also flows from fuse F8 and illuminates the 4-wheel steer warning light L1, going to earth through relay switches K1 and K2 via contacts 8/9. If the front axle is not in the straight ahead position when 4wheel steer is selected, the system remains in 2-wheel steer or crab steer mode, until the front axle is in the straight ahead position when the front axle proximity switch G is activated. The sequence is then as described in the first paragraph.

With the spools of steer mode valve D in the 4-wheel steer position there is a hydraulic connection between the steer unit C and the front and rear axle power track rods E1, E2. When the steering wheel is turned (right turn shown), oil is fed to the rear track rod E2 and the displaced oil is fed to the front track rod E1 via the spool assembly. The front track rod turns the wheels in the opposite direction to the rear wheels and displaced oil returns to tank. If the steering wheel is turned to the left, the oil flow is reversed and the machine will turn in the opposite direction. Machines to S/N 773053 The anti-cavitation valve D5 is integral with the steer mode valve assembly D. It prevents the possibility of steer ram cavitation occurring during the transition from a left turn into a right turn when 4-wheel steer is selected. High pilot pressure at port P opens the anti-cavitation valve and allows oil from the steering unit C to return to tank via anticavitation valve D5 port V. Low pilot pressure at port P closes the anti-cavitation valve, oil can not return to tank and is locked-in preventing cavitation of the rams. Machines from S/N 773054 The anti-cavitation valve D5 is by-passed as shown in inset Z opposite.

9803/3660

Issue 1


Section H


6-5


6-5

Steer mode control valve D - ports internally connected T→B A→P

335291

9803/3660

Issue 1


Section H


6-6


6-6

K 9 8 K3

K4

K5

10

K6

K2

9 8

10 K1

J

L1 H

L3

D D1

G

L2

D2

D3

D4

F13

F8

A172071

System Operation Crab Steering Electrical Circuits

Hydraulic Circuit

With the front axle in the straight ahead position and selector switch J in the the crab steer position, current flows from fuse F13 through the front axle proximity switch G, then selector switch J, to energise relays K3 and K6. Relay switch K1 contacts move to the 9/10 position and relay switch K2 contacts move to the 8/9 position. Current flows to energise solenoid D3, going to earth through relay switch K1 contacts 9/10 and relay switch K2 contacts 8/9. Current also energises solenoid D1, going to earth through relay switch K2 contacts 8/9. Current flows from fuse F8 and illuminates the crab steer warning light L3, going to earth through relay switch K1 contacts 9/10 and switch K2 contacts 8/9.

With the spools of steer mode valve D in the crab steer position there is a hydraulic connection between the steer unit C and the front and rear axle power track rods E1, E2. When the steering wheel is turned (right turn shown), oil is fed to the rear track rod E2 and the displaced oil is fed to the front track rod E1 via the spool assembly. The front track rod turns the wheels in the same direction as the rear wheels, causing the machine to crab to the right. Displaced oil returns to tank.

If the front axle is not in the straight ahead position when crab steer is selected, the system remains in 2 or 4-wheel steer until the front axle is in the straight ahead position when the front axle proximity switch G is activated. The sequence is then as described in the first paragraph.

If the steering wheel is turned to the left, the oil flow is reversed and the machine will crab in the opposite direction. Note: On machines from S/N 773054 anti-cavitation valve D5 is by-passed as shown at inset Z.

9803/3660

Issue 1


Section H



Fault Finding

8-1

Contents

8-1

Introduction Page No.

Introduction

8-1

Mechanical/Hydraulic

8-1

Steering wheel difficult to turn

8-1

Steering wheel turns on its own

8-2

Machine will not turn when the steering wheel turned.

8-2

Steering fails to respond to selected mode.

8-3

4WS phasing faulty

8-3

Electrical

8-5

The purpose of this section is to help you trace faults to a faulty unit (valve, actuator, ram, solenoid, proximity switch, etc). Once you have located the fault, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in this section, Section C - Electrics or Section E - Hydraulics as appropriate. To help identify electrical or hydraulic circuits, valves, rams etc mentioned in the fault finding procedures, refer to the electrical schematics in Section C - Electrics or the hydraulic schematic diagrams in Section E - Hydraulics. 1

Before you begin fault finding, read the Safety information at the beginning of this manual.

2

Make any relevant electrical checks before moving on to the hydraulics.

3

Make simple checks before say, stripping a major component.

4

Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

5

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

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.

Mechanical/Hydraulic Fault

1

Steering wheel difficult to turn.

Possible Cause

Action

Priority valve not operating correctly

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

Tyres not inflated to correct pressure

Inflate tyres to correct pressure



Leaks in the relevant hoses or component connections

Check hoses and connections for leaks

Air in the hydraulic system.

Bleed system - bleed the load sense line. ....... continued

9803/3630

Issue 1


Section H

www.WorkshopManuals.co.uk Steering Fault Finding

8-2 Fault 1


Possible Cause

Steering wheel difficult to turn. (continued)

8-2 Action

Low pump flow.

Check pump flow, if required service or replace pump.

Steer relief valve set incorrectly

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

Worn or damaged parts in the steer control valve.

Remove and inspect.

Steer mode valve not operating correctly

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

2

3

Steering wheel turns on its own.

Machine will not turn when the steering wheel turned.

Mechanical failure

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.

Correct as required.





Air in the hydraulic system.

Bleed system - bleed the load sense line.

Low pump flow.

Check pump flow, if required service or replace pump.

Steer relief valve set incorrectly

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

Worn or damaged parts in the steer control valve.

Remove and inspect.

Priority valve not operating correctly

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

9803/3630

Issue 1


Section H

www.WorkshopManuals.co.uk Steering Fault Finding

8-3 Fault 3


8-3

Possible Cause

Machine will not turn when the steering wheel turned (continued).


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

* 4

Steering fails to respond to selected mode

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 damage, 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 in accordance with mode selected (see Steer Mode Valve, Checking Solenoid Operation).

5

4WS phasing faulty



Electrical failure

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

See 4WS Phasing Faulty on following page.

-

9803/3630

Issue 2*


Section H



8 -4

Fault Finding

8 -4

4WS Phasing Faulty Ensure system is reDoes steering goes out of No phased after four hours of phase in less than four continuous use (see hours of continuous use? Operator’s Handbook) Yes

START

Ensure operator changes Does steering go out of Yes steer mode at low engine phase by a small amount speed and observes 5 & drift no further when second delay between changing steer modes? modes (see Operator’s Handbook) No OK NOW?

DONE

*

No

Ensure power track-rod piston is centralized and wheel tracking is correct. Adjust alignment of steer sensors to optimise accuracy.

DONE

Yes Bleed steering system to Yes remove air. OK NOW ?

DONE

No † Possible leakage through anti-cavitation valve. By-pass the anticavitation valve as described in T.I. 5/180. Irrespective of the outcome of this test do not re-instate the pipework. OK NOW?

Yes

No *

Check both front and rear power track rods for internal leakage. Strip and inspect (see Power Track Rod). Check No correct seal/energising ring fitted, check for seal damage, scoring or bore ovality. Re-seal or renew faulty unit(s). OK NOW? Yes DONE

DONE It is likely that one of the preceeding tests was not conclusive. Repeat.

START

No Check for contamination in the hydraulic system which can can cause one Yes of the already detailed problems. Is system contaminated?

Filter the hydraulic system.

No START Strip steer mode valve and inspect spool for scoring or damage. Renew valve if required. OK NOW? Yes DONE * † Note: On Machines from S/N 773054 onwards the anti-cavitation valve will already have been bypassed ex-factory. Proceed to the next check.

9803/3630

Issue 2*




www.maskinisten.net


Section H

Steering

8-5

Fault Finding

Section Hwww.maskinisten.net 8-5

Electrical START

Is there a problem with the steering system or in selecting steer modes? YES Check fusible link FL1 and FL2 and fuses B1-8 and FB2-13. Are they OK?

NO

DONE

START

NO

START

Renew fuse or fusible link.

YES Locate the front and rear proximity switches. Are they and the wiring in the immediate vicinity free from physical damage? YES Are the steer modes changing when selected, but the wheels are slightly off the straight ahead position when changing mode occurs?

NO

YES

Repair wiring/renew proximity switch as appropriate.

START

Renew front proximity switch. Disconnect the front and rear proximity switches, and fit a jumper wire from pin 3 to pin 1 at connectors C19 and C21. Are you able to change steer modes now (with the wheels pointing in any direction).

NO

YES

NO

Reconnect the front proximity switch only. Can 4WS and crab steer modes be obtained?

Remove the steer mode switch and check that with the switch in each mode position, the respective terminals (and only these terminals) are connected. Is the switch working OK?

START

Repair earth wire 601BJ from C3 to C23.

START

Select 4WS and locate the front proximity switch. Insert a metallic object (e.g. screwdriver) in front of its face for 2 seconds. Can the steering wheels be aligned now?

Check for continuity between pin 8 of C7 and ground. Is continuity experienced?

NO

Disconnect BHC1 and BHC2. Check for continuity between the pins shown below and ground in the relevant steer mode. 4WS : Pins 15, 16 2WS : Pins 14 Crab Steer : Pins 15, 17 Continuity OK?

START Check and repair wire 106C to pin 10 of C11.

NO Is the machine stuck in a specific steer mode, and you are unable to change it? NO

DONE

YES

Check for 12V between pin 10 of C11 and ground. Is 12V experienced?

With the ignition on, check for 12V between pin 1 and ground of connectors 13, 14, 15 and 16. Do they all have a 12V supply?

NO

START

Renew steer mode switch.

START

Repair earth wire 601W.

START

NO

NO

YES

NO Are steer modes changing correctly, but the instrument panel in the cab is not displaying the mode selected?

Renew rear proximity switch.

YES

YES

YES

YES

YES

YES Having tried all steer modes, are wheels facing in their maximum lock positions, with the steering wheel effectively ‘locked’?

YES

NO Set-up proximity switches as detailed within this technical manual.

NO Check for continuity between pin P of C3 and ground. Is it OK?

NO

YES

NO

Check the steer mode indicator bulbs in the rear of the dashboard and renew as necessary.

START

Inspect and repair the chassis harness between BHC1 and C14, C15 and C16

Repair damaged 12V wire to the specific solenoid (109F, 109E, 109C or 109D respectively), as necessary.

START

START

Repair damaged 12V wire 109B from connector BHC2.

START

Renew relevant solenoid

START

At C7, check for 12V between the pins shown below and ground in relevant steer mode: 4WS : Pin 5 2WS : Pin 1 Crab Steer : Pin 2 Is 12V experienced? YES

NO

Renew steer mode control unit.

START

Inspect and repair the cab harness between C7 and BHC2.

START

YES Check for 12V between pin 3 and ground of the proximity switch connectors C21 and C19. Do they both have a 12V supply?

NO

YES Select 4WS. Steer the wheels through the straight ahead position from the left and from the right. Check for continuity between pin 2 of C14 and ground and pin 2 of C15 and ground. Is continuity experienced?

NO

YES Repeat this procedure for 2WS (C13 and ground) and crab steer (C14 and C16 and ground), checking for continuity. Is continuity experienced?

NO

YES Reconnect the connectors to the solenoids and check for correct solenoid energisation in each steer mode using a metallic tool to check magnetism. Are the correct solenoids energised?

NO

YES Problem lies internally within steer mode valve. Remove and repair as necessary.

START

9803/3630

Issue 2*




www.maskinisten.net



www.maskinisten.net

Section H

www.WorkshopManuals.co.uk Steering *Servicing

9-1

Procedures


9-1

System Bleeding For Machines with Rotary Instrument Panel Switch for Steer Mode Selection Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows. 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


3

Turn steering wheel to left, until front wheels are fully locked to the left.

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


5

Turn steering wheel to left, until the front wheels are fully locked to the left.


6


7

Turn steering wheel to left, until front wheels are fully locked to the left.


8


Turn steering wheel to left, until the front and rear wheels are fully locked.

9803/3630

Issue 3*


Section H

www.WorkshopManuals.co.uk Steering *Servicing

9-2


Procedures

9-2

System Bleeding For Machines with Manual Steer Mode Selector Whenever any hydraulic steering component is disconnected or removed the system must be bled as follows. 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

Start the Engine

2

Select 2 Wheel Steer

6

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. c Turn steering wheel to left until front wheels are in the straight ahead position.

Select 2 Wheel Steer a b c d

a

7

Turn steering wheel to full right lock. Turn steering wheel to full left lock. Turn steering wheel to full right lock. Turn steering wheel to left until front wheels are in the straight ahead position.


3

Turn steering wheel to left, until front wheels are fully locked to the left. b Turn steering wheel to right until front wheels are in the straight ahead position.


Turn steering wheel to left, until front wheels are fully locked to the left. b Turn steering wheel to right until front wheels are in the straight ahead position. 4

8

a b c d

Select 2 Wheel Steer a b c d


Select 2 Wheel Steer

9


5


Turn steering wheel to left, until the front wheels are fully locked to the left. b Turn steering wheel to right until front wheels are in the straight ahead position.

10


Turn steering wheel to left, until the front and rear wheels are fully locked.

Stop the Engine a

Top up the hydraulic level as required.

9803/3630

Issue 2*


Section H


* Checking

10 - 1

Servicing Procedures

10 - 1


the Steering Pressure

1

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

2

Lower the forks to the ground. Stop the engine and remove the starter key.

3

Turn the steering wheel to the left and to the right several times to vent system pressure.


A

5-3-2-1-/1

4

Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure gauge (892/00279) to test point A.

Note: From machine serial number 771429 test point A is located on the priority valve. 5

Start the engine and run at 1500 rev/min and turn the steering wheel to full lock. Hold the wheel on full lock and check the gauge reading. This should be equal to the relief valve pressure (175 bar - 2540 lbf/in2). See Technical Data.

Adjust the steering valve if a high or low pressure reading is indicated.

Adjusting the Steering Pressure Note: From serial number 773663, pressure adjusting screw C can be accessed through a cut-out at the base of the steering column on machines after first removing the panels.

A A326070

It may be necessary to remove the steering valve if access is restricted. 1

Remove plug B on the steering valve (8 mm AF).

2

Adjust screw C (6 mm AF) until the correct pressure is shown on the gauge.

C B

342770

9803/3630

Issue 2*




www.maskinisten.net

Section H 11 - 1



Servicing Procedures

11 - 1


A

A D

B A312102

E

C

263930


D

E

C

B A A312101

Double Pump

E D

C

B A 416111

9803/3660

Issue1


Section H

www.WorkshopManuals.co.uk Steering Servicing Procedures

11 - 2


11 - 2

Priority Valve - Cleaning The priority valve spool and spring may be removed for cleaning with the pump fitted to the engine. Carry out the general safety procedures detailed under Machine Safety in Section 3. Disconnect hose A. Unscrew adapter B and extract the priority valve spring. Remove the blanking plug C and extract the priority valve spool. Clean these components in clean paraffin paying particular attention to the orifices at each end of the spool. Dry off and lubricate with clean hydraulic fluid. Refit the priority valve spool and install blanking plug C. Refit the priority valve spring and install adapter B. Torque tighten both as per table below. Check the machine operates correctly and for hydraulic leaks. Torque settings Item B C

Nm 100 - 105 75 - 81

Kgf. m 10.2 - 10.7 7.6 - 8.3

lbf. ft 74 - 77 55 - 60

Priority Valve - Standby Pressure Testing Connect a 0 - 70 bar (0 - 1000 lbf/in2) pressure test gauge (892/00346) as follows: Disconnect hose D and install the pressure gauge in its place. Connect the now freed hose D to a clean container via a suitable hose in order to collect any oil drainage. Disconnect hose A from load sensing port adapter B and blank off. Set the steering to neutral, i.e. do not turn the steering wheel, and start the engine. Gradually increase engine speed to 1000 rev min while checking the maximum pressure gauge reading which should be 5.9 to 8.7 bar (86 to 126 lbf/in2). If the pressure is outside the limits clean the priority valve (see Priority Valve - Cleaning). If cleaning fails to rectify, check the steering pump section flow rate and pressure (see Hydraulic Pump, Removal and Replacement in Section E). If these tests are satisfactory renew the priority valve (see Priority Valve, Removal and Replacement, this Section).

9803/3660

Issue 1


Section H

www.WorkshopManuals.co.uk Steering Power Track Rod

12 - 1


12 - 1

B C A

M

J K P

L

K

J

L N

F G E

H D

A312030

M

9803/3630

Issue 2


Section H



Power Track Rod

12 - 2

12 - 2

Removal Carry out the general safety procedures detailed under Machine Safety, Section 3.

7

! 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.

Rear Axle Use a suitable jack to raise the left end of the axle so as to swivel the right end down to make room for removal of the power track rod. Using a soft-faced hammer, gently tap the closed end of the track rod cylinder to the right and out of its mounting.

Replacement

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

Replacement is the reverse of Removal.

GEN-001

Note the following:

Before commencing work clean the power track rod and adjacent areas of the axle. Proceed as follows:

1

Grease and renew the two web seals in each link arm eye, making sure they are fitted correctly and fully seated.

2

Grease the machined external shoulders of the power track rod and install by tapping with a soft-faced hammer on the mounting flange.

Front Axle Disconnect hoses A and B and then remove adapter C. Blank off the hoses and plug the adapter at A and the port vacated by adapter C to prevent the ingress of dirt.

3

Take care to align the marks made at step 4 of Removal.

Rear Axle Disconnect pipe assembly D from the power track rod at points E and F. Remove mounting screw G. Lift the pipe assembly clear and blank both open ends to prevent the ingress of dirt. Remove adapter H and plug the port vacated as well as the port E.

Item

Nm

kgf m

lbf ft

G H J M N/P

56 56 56 166 600

5.7 5.7 5.7 17 60

41 41 41 122 440

1

2

As appropriate, use suitable lifting gear to raise the front or rear wheels off the ground and block the chassis. Remove the left front or right rear wheel respectively.

Torque Settings

Note: As this point, if the power track rod is to be dismantled, loosen the track rod link arms (see Power Track Rod, Link Arms, Removal and Replacement) while the track rod is still securely clamped. 3

Remove screw J and pin K at each end of the axle and separate the link arms L from their mounting points. Discard the two web seals seated in the eye of each link arm.

4

Make alignment marks on the cylinder flange and end cover of the power track rod and on the housing flange of the axle.

5

Remove the four mounting screws M.

6

Front Axle Using suitable jacks, support both ends of the axle and then remove mounting nuts N at both ends. Leave bolts P in position. Lower the jack at the left end sufficient to make room for removal of the power track rod. Using a soft-faced hammer, gently tap the closed end of the track rod cylinder to the left and out of its mounting.

9803/3630

Issue 2


Section H

www.WorkshopManuals.co.uk Steering * Power

13 - 1


13 - 1

Track Rod

Link Arms Removal and Replacement

M L

A311980

P C E

B

N

A

D A311970

S300370

X

Y A318960

9803/3630

Issue 2*


Section H


13 - 2


13 - 2

Track Rod

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: If the power track rod ram is to be dismantled, carry out the procedure (see Power Track Rod, Dismantling and Assembly) before replacing/renewing the link arms.

1

2

Fix the assembly on a locally made strip/rebuild bench as shown. a

Use two suitable open ended spanners at L and M reacting against each other until one ball joint unscrews. For the purposes of explanation assume the ball joint at L has unscrewed.

b Unscrew the ball joint until an open ended spanner can be fitted on rod N. Screw the ball joint against the spanner to secure it and to prevent damage to the rod.

Replacement is the reverse of removal but note the following: 1

Remember to fit target disc C (where applicable).

2

Use JCB Threadlocker & Sealer on the first three threads of the inner ball joint where it screws into the end of the track rod.

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.

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. c

3

By reacting against the spanner at N undo the other ball joint at P.

To adjust the wheel alignment undo the lock nuts E. Turn the threaded adjusters D equally to obtain the correct alignment. Tighten the lock nuts E.

Where applicable remove target disc C. 4

Note: If the inner or outer ball joints need to be renewed, then a replacement link arm assembly must be fitted.

Check the target disc/proximity switch setting (where applicable) (see Proximity Switches, Adjustment in Section C).

Torque Settings Item A/B D/E

Nm 240 - 260 240 - 260

Kgf m 24 - 26 24 - 26

9803/3630

lbf ft 177 - 192 177 - 192

Issue 2*


Section H


14 - 1


14 - 1

Track Rod

A

B

3 11 6 8 9

10

12

4 1 5 7

10

F 2

C

11

D

E 7

8

6

9 A312060

9803/3630

Issue 2*


Section H


14 - 2

Power Track Rod

14 - 2


Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. Note: Items 1, the mounting bolts, and 4, the mounting flange, on the axle are included for completeness but do not constitute part of the power track rod. For assembly the sequence should be reversed. When Dismantling Fix the ram assembly on a locally manufactured strip/rebuild bench as shown at A. If not already done, remove the two steering link arms B and C (see Link Arms, Removal and Replacement). Remove end cap 2 and then pull the piston rod assembly 5/6/7/8/9 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 the bench in place of the ram cylinder. Remove and discard the wear rings 6, 7 and seal 8/energising ring 9. 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.

When Assembling Use a JCB Cleaner & Degreaser to ensure that all threads are free from grease, hydraulic oil and old JCB Multi-Gasket. Allow 15 minutes for solvent to dry before applying fresh JCB Multi-Gasket. Ensure that lubricants used during assembly do not come into contact with JCB Multi-Gasket. Ensure that piston rod seals 10 and wiper rings 11 are fitted correctly into the closed end of cylinder 3 and also into cover 2 along with cover seal 12. It is very important that energiser ring 9 is not twisted. Failure to carry out the installation correctly could lead to hydraulic fluid leakage between the two sides of the power track rod and consequential steering problems. After installation check that three white marks are visible on the outside diameter arrowed in view E before installing seal 8. Before installing piston rod assembly 5/6/7/8/9 apply grease to piston seal 8 and to the surfaces of the piston rod. Clamp the cylinder vertically and lower the piston rod assembly in from the top, as shown at D, making sure its orientation is correct, i.e. with piston sleeve F nearest the closed end of the cylinder. 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 seals carefully into the cylinder. If the piston head wear rings or seals are damaged during this stage, they must be renewed. 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.

9803/3630

Issue 2


Section H



Priority Valve

20 - 1

20 - 1


A D

F

E

D

E

* Triple Pump (Machines from S/N 771430)

G A

D

E

G A 9803/3630

* Double Pump

Issue 4*


Section H

www.WorkshopManuals.co.uk Steering Priority Valve

20 - 2


20 - 2

Removal and Replacement Removal Disconnect hoses A, D, E and blank off to prevent the ingress of dirt. Remove the four mounting screws F (on early machines) or the three socket head screws G (on later machines) and lift the priority valve assembly away from the pump. Remove and discard all ‘O’ ring seals between the mounting faces of the priority valve assembly and the pump. Replacement Replacement is the reverse of Removal. Lightly grease and fit new ‘O’ rings between the mounting faces. Tighten the mounting screws evenly and progressively to the torques below. Torque Settings Item F G

Nm 100 30 ±4

kgf m 10.2 3 ± 0.4

lbf ft 74 22 ± 3

Dismantling and Assembly The priority valve assembly is not serviceable beyond the removal of foreign matter (see Priority Valve - Cleaning, this section). A faulty unit must be replaced.

9803/3630

Issue 3*


Section H



23 - 1

Steer Mode Valve

23 - 1


Removal

The solenoids operate according to the steer mode selected (see table below). Operation (energisation) of a solenoid can be easily detected by placing a steel object (e.g. screwdriver blade) close to the outer casing. A magnetic attraction of the steel object towards the solenoid indicates energisation.

1

Disconnect the hoses at A and B. Label the hoses and cap the ends to prevent the ingress of dirt.

2

Disconnect the electrical connection C to each of the solenoids. Label each connector before removal.

3

Unscrew retaining screws D and remove the valve.

Mode Selected

Solenoid(s) Energised

2WS

W

CRAB

X, Y

4WS

X, Z

Note: Ports C and V are not used on machines from serial number 773054 (see Technical Bulletin 5/180 [E186 N.Am] for details of bypassing the anti-cavitation valve).

Replacement If a solenoid is not energised proceed as follows until the reason is established:

Replacement is the reverse of Removal.

a

Torque Settings

Check that fuse 13 is intact. If not, renew and then check that all steer mode solenoid combinations function correctly.

b

If the fuse is intact remove the electrical connector from the malfunctioning solenoid(s) and check that the 12V supply is present across the connector pins. If not, check the supply circuit.

c

Check the solenoid resistance which should measure a few ohms (if unsure compare with a known good solenoid). Renew the solenoid if the reading indicates a short circuit (zero ohms) or open circuit (infinite resistance). If a reading somewhere between the two is obtained reverse the two instrument probes and repeat for a valid check.

Item D

Nm 28

kgf m 2.9

X

A C

P

B V

W

lbf ftp 21

T

A B

Z Y

C

D

9803/3630

A292780

Issue 2


Section H



24 - 1

Steer Mode Valve

24 - 1

Dismantling and Assembly Before starting dismantling of any part of the steer mode valve obtain the repair seal kit which includes replacement items, 9, 13, 15, 17, 19, 21, 23, 26.

When Assembling

The numerical sequence on the diagram is intended as a guide to dismantling. For assembly the sequence should be reversed.

Do not exceed the torque tightening figures below.

Note 1: The illustration depicts a complete strip down, but to carry out specific servicing/repairs, e.g. renewal of one of solenoids 14 and 18, it is only necessary to dismantle the relevant components.

Item 1, 4 8 10 20, 22

Lightly grease and renew all seals that have been disturbed.

Torque Tightening

Note 2: None of the component parts of CETOPS valve assembly 20 - 25 can be renewed individually. The extent of permissible servicing is cleaning and the consequential renewal of seals 21 and/or 23. If damage to any component or distortion of the spool is evident renew the complete assembly.

Nm 8 50 44 25

kgf m 0.82 5.1 4.5 2.6

lbf ft 5.9 37 32 18

Note: Ports C and V are not used on machines from serial number 773054 (see Technical Bulletin 5/180 [E186 N.Am] for details of bypassing the anti-cavitation valve).

20 4

14

13 12

5

19

1

6

2

15 21

25 26 23

3 24

9 8 16 17 11 18

10 22 A313790

9803/3630

Issue 2




www.maskinisten.net

Section H


30 - 1

Hydraulic Steering Unit

30 - 1


Removal and Replacement 1

Switch off the engine and remove the starter key. Ensure that all hydraulic pressure is dissipated.

2

Ensure that the steering wheel is in the straight ahead position.

3

Disconnect the hydraulic hoses to steering unit A, labelling them to aid reconnection. Plug the ports and hoses to prevent the ingress of dirt and excessive loss of hydraulic oil

4

Mark the orientation of steering unit A to splined shaft B.

5

Remove bolts C (4 off) from inside the cab. At the same time have an assistant support steering unit A beneath the machine.

6

Withdraw steering unit A.

Replacement Replacement is the reverse of removal . Note: The steering unit is spring loaded to the neutral position (i.e. straight ahead). Make sure the steering wheel is in the straight ahead position when re-connecting splined shaft B. Torque tighten fixing bolts C to the figures given below. Torque Settings Item C

No. off 4

Nm 45

kgf m 4.6

B

lbf ft 33

C A

A268450

9803/3630

Issue 1


Section H 35 - 1

www.WorkshopManuals.co.uk Steering Hydraulic Steering Unit


35 - 1

S10221A

9803/3630

Issue 1


Section H



35 - 2


35 - 2

* Machines to Serial No. TBA Dismantling Use the numerical sequence on page H/35-1 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 JCB Threadlocker and Sealer. 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 illustration.

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 to 17 facing away from bearing 18.

11

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

9803/3630

Issue 1


Section H



35 - 3


35 - 3

Machines to Serial No. TBA (cont’d) Assembling (continued) 7

Invert unit and place on a suitable hollow support so that body does not rest on protruding sleeve, thus preventing displacement of the new seals. Place ball 23 into check valve hole and fit bush 22.

9

11

10 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.

22 23

B

7

C

S229700

10

11

12

13

14

Use a suitable piece of rigid flat material, 0.25 mm (0.010 in) thick, to support the shaft and ensure positive engagement with the splines of rotor 7.

4 1

Locate rotor onto shaft, ensuring alignment as at C. Fit spacing bush 6 into rotor.

5

Fit ‘O’ rings 4 and 8 each side of body 5, then position body over rotor.

8

Refit the end plate and fit at least one bolt 2 before removing support material. Fit remaining bolts, ensuring that special bolt 1 is correctly located. Tighten all bolts to 29 Nm (22 lbf ft).

6 2 7

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 175 bar (178 kgf/cm2, 2500 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/Degreaser, allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat threads of screw 31 with JCB Threadlocker and Sealer. Assemble screw to depth measured during dismantling (see page H/35 - 2) then fit plug 29 and washer 30. 9803/3630

Issue 1




www.maskinisten.net

Section H




36 - 1

36 - 1

0 7

@

8

! 6 £

3

$ & ^

4

5

* (

)

2

1

9

¤ ⁄

% ›

‹

S210620

9803/3630

Issue 1


Section H




36 - 2

36 - 2

Machines from Serial No. TBA Dismantling Use the numerical sequence on page H/36 - 1 as a guide to dismantling. Before removing items 11 to 14, rotate the spool and sleeve assembly within the housing until the pin 21 is horizontal. Push the spool and sleeve assembly from the housing just far enough to free the gland bushing 11. Inspecting Examine all contact surfaces and replace any parts that have scratches, wear or other damage that could cause leakage. Do not use abrasive or try to file or grind the surfaces. Clean all metal parts with a solvent and blow dry with air.

Assembling 1

Assemble the check valve Lower check ball retainer 20 into the housing. Make sure the retainer is straight in the valve hole and not on its edge. Fit check ball 19 into housing. Lubricate and fit O rings (A 11.1 mm (5/8 in.) B 15.9 mm (7/16 in.)) to check seat 18. Install check valve seat 18 into the housing open end first; push the seat fully into the housing taking care not to twist and damage the O rings. Fit the set screw 17 and tighten to 11 Nm (8.1 lbf ft2).

& A

*

B

( )

Note: When fitted the top of the set screw should be slightly below the housing top surface.

2

S210630

Assemble the spool and sleeve Assemble the spool 23 and sleeve 24 so that on completion the spring slots A line up at the same end. Rotate the spool when sliding the parts together and test for free rotation.

A A ‹ › S210640

3

Fit the spring assembly Make sure the spring slots are lined up and insert the spring installation tool (Eaton part number 60057) through the slots. Assemble a set of low torque springs 22, extend edge downward, with a pair of spring spacers B between two sets of centering springs C. Insert one end of the spring set into the installation tool. Compress protruding springs and push set into the slot at the same time withdraw the installation tool. Centre the spring set in the spool and sleeve assembly so that they push down evenly and are flush with the upper surface of the assembly. Fit pin 21 to the assembly making sure it is flush both sides of the sleeve 24.

C C

¤ B

A

›

9803/3630

S210650

Issue 1


Section H




36 - 3

36 - 3

Machines from Serial No. TBA (cont’d) Assembling (continued) 4

Installing the spool and sleeve assembly Position the spool and sleeve assembly so that the splined end of the spool enters the valve housing as shown. Push the assembly gently into place with a slight rotating action until the parts are flush at the insertion end face A. Check for free rotation of the spool and sleeve assembly within the housing by applying finger tip force to the spool splined end.

A

S210660

Note: Do not move the spool and sleeve assembly beyond the flush position because the pin 21 may drop into the housing discharge groove. 5

Fit the drive end seals a

Place the housing 25 upright on a clean lint free cloth. Lubricate all seals before assembly. Fit seals 16 and the bearing race components 14 into the housing.

$ ^

S210670

b

Assemble the Teflon seal components 13 (seal A, 'O' ring B and back up ring C) above the bearing race 14.

C £ A

B $

^

S210680

c

Fit the dust seal 12, flat smooth side down, into the gland bushing 11. Assemble the gland seal bushing over the splined end of the spool 15 and tap the bushing into place with a soft faced hammer, making sure the bushing is flat against the bearing race. Fit the retaining ring 10 pressing it into position around the spool sleeve 24 with a screwdriver blade.

0

›

@

(

!

! % 9803/3630

S210690

Issue 1


Section H




36 - 4

36 - 4

Machines from Serial No. TBA (cont’d) Assembling (continued) 6

B

Fitting the meter end seal and drive Insert seal 9 into housing 25. Fit spacer plate 7 together with its seal 8 and align with housing bolt holes. Rotate the sleeve and spool assembly 15 until it is seen that the pin 21 is parallel with face A. Fit the drive 6 making sure it is fully engaged with the pin. Mark the drive head as shown at B.

6 8 7 A

9 fi

S210700

7

Time and fit the meter Fit seal 4 into the groove on the meter 3. Position the meter so that the seal is away from the housing 25 and align the meter valleys as shown at C. Reference lines A, B and C should be parallel. Fit the meter over the drive head 6 and align the bolt holes without disengaging from the drive.

4 3

C B

6

fi

A

S210710

8

Fit and secure the end cap Fit any drive spacers 5 that are required. Locate the end cap 2 over the meter and align the bolt holes. Fit seven cap screws 1 and pre tighten to 17 Nm (12.5 lbf ft). Finally, viewed from face A torque tighten the screws to 31 Nm (22.9 lbf ft) in the sequence shown.

A

A S210720

9803/3630

Issue 1




www.maskinisten.net

Section K

www.WorkshopManuals.co.uk Engine

i

www.maskinisten.net Section K

i

Contents

Page No.

Technical Data

1-1

General Description

1-2

Radiator Removal and Replacement

3-1

Engine and Transmission Removal and Replacement

4-1

Separating the Engine and Bevel Box

5-1

* Fuel Lift Pump

10-1

9803/3630

Issue 3*


Section K


1-1


1-1

TECHNICAL DATA Type

JCB diesel engine, 4 cylinder, water cooled AA - 50590, naturally aspirated 76HP AB - 50592, turbocharged 96HP AB - 50645, turbocharged 106HP 85A Alternator AB - 50591, turbocharged 106HP 65A Alternator AR - 50659, naturally aspirated, 80HP AK - 50667, turbocharged, 102HP 65A Alternator AK - 50671, turbocharged, 102HP 85A Alternator AM - 50822, turbocharged, intercooled 120HP 85A Alternator

Bore (nominal): AA, AB, AK, AM Builds AR Builds

100mm (3.937 in) 103 mm (4.055 in)

Stroke

127mm (5.000 in)

Swept Volume AA, AB, AK, AM Builds AR Builds

4 litres (243 in3) 4.23 litres (258 in3)

Compression Ratio AA, AB Builds AR, AM Builds AK Builds

16.5 : 1 17.25 : 1 18.5 : 1 28 bar (400 lbf/in2) maximum variation between cylinders 3.5 bar (50 lbf/in2) 1,3,4,2 - Inlet 0.20mm (0.008 in) - Exhaust 0.45mm (0.018 in)

Compression Pressure Injection Sequence Valve Clearance - Cold

Idling Speed

750 rev/min (AA, AB) 800 rev/min (AR, AK, AM)

Maximum Governed Speed

2200 rev/min

Maximum No-load Speed AA, AB Build AR, AK, AM Build


Injection System Details

- refer to appropriate Engine Service Manual (see below)

Lubrication System Oil Pump type Oil Pressure (Hot) at maximum speed: AA Builds AB, AK, AM Builds AR Builds Cooling System * Fan Speed (to machine 784534) Fan Speed (from machine 784535) Coolant Pressure Coolant Temperature (Normal) Temperature Warning Light operates at:

Eccentric rotor 2.1 bar (30 lbf/in2) 2.6 bar (40 lbf/in2) 2.0 bar (29 lbf/in2)

2200 rev/min (at maximum no-load speed of engine) 1800 ± 100 rev/min (at maximum no-load speed of engine) 1 bar (14.5 lbf/in2) 80-85 °C (176-185 °F) 98 °C (208 °F)

For further engine details see Engine Service Manual, Publication No. 9806/0100 (AA and AB builds), 9806/2140 (AR, AK & AM builds).

9803/3630

Issue 7*


Section K


1-2


1-2

GENERAL DESCRIPTION The machine is powered by a JCB diesel engine. One of several different versions of the engine may be fitted, see Technical Data. A conventional, belt-driven alternator is fitted, but the engine cooling fan is driven by a hydraulic motor. The motor is driven by * a section of a double or triple pump which is mounted onto the bevel box and driven by the output shaft. A relief valve is incorporated in the motor to limit the fan speed and a non-return valve allows the fan to 'free wheel' in the event of a sudden drop in engine speed. An electric fuel shut-off valve in the fuel injection pump is controlled by the starter switch. When the switch is turned to the off position the valve closes, cutting off the fuel supply and stopping the engine. Bolted to the flywheel is a damper which reduces torsional vibration and noise. The torque converter is fitted to the output shaft of the bevel box.

9803/3630

Issue 3*


Section K

www.WorkshopManuals.co.uk Engine Radiator

3-1


3-1

A H

S263531

J

K G

K E C

D F

B

A296450

9803/3630

Issue 2


Section K



Radiator

3-2

Removal

3-2

Removal - Machines with Air Conditioning

* Machines to M784534

! WARNING The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap.

Note: The air conditioning system is a closed circuit. DO NOT disconnect any of the pipes or hoses in the air conditioning circuit. 1

Carry out steps 1 to 8 of Removal - above.

2

Support the condenser and receiver drier assembly L.

3

Remove the 4 fixing bolts M at each side of the radiator. Do not allow the assembly to ‘hang’ on any of the connecting pipes or hoses.

4

Carry out steps 9 and 10 of Removal, above.

INT-3-2-9/1

1


2

Remove the engine cover - see Engine Removal, Prepare the Machine.

3

Access to the radiator assembly is made easier if the engine pod base is removed - see Engine Removal, Prepare the Machine.

4

Carefully loosen cap A. Let any pressure escape. Remove the cap.

5

Disconnect bottom hose B and drain coolant.

6

Label, disconnect and blank fan motor hydraulic hoses C and D and transmission cooler hoses E and F.

7

Disconnect top hoses G and H.

8

Disconnect heater hose J.

9

Support the radiator assembly, unscrew bolts K and remove radiator complete with fan and fan motor.

10

If necessary, remove the radiator from the fan/bracket assembly by undoing the fixings at each corner of the radiator.

M

M L

Replacement Replace the radiator by reversing the removal procedure. A296500

After replacement refill radiator, run the engine and check the fan motor speed. Replenish the hydraulic tank as required.

9803/3630

Issue 2*


Section K


3-3


3-3

A N

D

S263531

E F M

J

411710

K

L H

G

B

C

9803/3630

Issue 1


Section K


3-4

Removal Conditioning


Machines

Without

Air

3-4

Removal - Machines with Air Conditioning Machines from M784535

Machines from M784535

! WARNING

! WARNING

The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap.

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.

INT-3-2-9/1

4-3-4-1/2

Note: The following procedure applies to machines WITHOUT AIR CONDITIONING. For machines with air conditioning, see Removal - Machines with Air Conditioning

Note: Before carrying out the following procedure, the air conditioning must be discharged by a qualified person. See Air Conditioning Option - Safety Procedures in Section B.

1


2

Remove the engine cover - see Engine Removal, Prepare the Machine.

3

Access to the radiator assembly is made easier if the engine pod base is removed - see Engine Removal, Prepare the Machine.

4

Carefully loosen cap A. Let any pressure escape. Remove the cap.

5

Disconnect the oil temperature sensor electrical connector B.

6

Disconnect bottom hose C and drain coolant.

7

Label, disconnect and blank fan motor hydraulic hoses D and E. If the machine has the optional reversible fan, disconnect fan drain connection F.

8

Disconnect transmission cooler hoses G and H.

9

Disconnect top hoses J and K.

10

Disconnect heater hose L.

11

Disconnect air induction hose M.

12

Support the cooling pack assembly, unscrew bolts N and remove cooling pack complete.

13

Dismantle the cooling pack as necessary. Remove the radiator from the fan/bracket assembly by undoing the fixings at each corner of the radiator.

1

Carry out steps 1 to 11 of Removal - Machines Without Air Conditioning.

2

Disconnect the air conditioning hoses at P and R.

3

Carry out steps 12 and 13 of Removal - Machines Without Air Conditioning.

P R

390201

Replacement Replace the radiator by reversing the removal procedure. After replacement refill radiator, run the engine and check the fan motor speed. Replenish the hydraulic tank as required.

9803/3630

Issue 1


Section K



4-1

4-1

G A G

B

G G D

D C

G

E

E

G

F A296420

9803/3630

Issue 1


Section K


4-2


4-2

Engine and Transmission - Removal and Replacement If the bevel box or transmission need to be dismantled, the engine, bevel box, transmission and hydraulic pump must be removed from the machine as a complete assembly. Most servicing can be carried out with the engine in situ, however the following procedure details the engine, bevel box and transmission removal procedure. Prepare the Machine 1

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

2

Disconnect the battery or switch off battery isolation switch.

3

Remove engine cover A. Remove the bolts from hinges B and unscrew gas strut C from the radiator cowl.

4

Remove the air filter. Loosen clips D on the pipes to the engine and pre -cleaner. Undo fixing bolts E and remove the filter assembly. Cap the air intake manifold inlet with tape or similar to prevent ingress of dirt etc.

5

Remove engine pod base F. Support the pod. Remove six bolts G and lower the pod complete with guards to the ground.

6

Remove the radiator and cooling fan assembly (see Radiator - Removal and Replacement).

Note: Unless the machine is fitted with air conditioning, access to the engine is made easier if the radiator is removed.

9803/3630

Issue 1


Section K



4-3

4-3

C M

F

B

A E

B

L

G

J

N D

H

A296470

9803/3630

Issue 1


Section K


4-4


4-4

Engine and Transmission - Removal and Replacement (cont’d) Prepare the Engine for Removal Note: The illustration shows some, but not all the ancillaries connected to the engine. 1

Remove header tank A. Unscrew mounting bracket bolts (2 off), disconnect the two pipes B and remove assembly from the engine.

2

Disconnect the transmission filler/dipstick bracket C from the engine.

*3

Disconnect: i ii iii iv

4

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 ii iii iv v vi vii viii ix

5

Starter motor Alternator Coolant pressure switch Coolant temperature sender Engine oil pressure switch Engine temperature sender Engine shut off solenoid Ether cold start (if fitted) Air conditioning compressor (if fitted)

If air conditioning is fitted: The air conditioning is a pressurised closed loop system, do not disconnect the hoses to the compressor. Leave the hoses to the compressor intact. i ii iii iv

6

Throttle cable D. Fuel leak-off pipe E. Suction line from the fuel lift pump F. Heater hose G or H (dependent on machine).

Remove the belt from the clutch of the air conditioning compressor. Disconnect the electrical connectors at the compressor. Undo and remove the air conditioning compressor retaining bolts. Put the air conditioning compressor out of the way (do not allow the compressor to ‘hang’ on its hoses).

Disconnect exhaust from the manifold L and detach from chassis side plate at M.

9803/3630

Issue 2*



Section K


4-5

4-5

*

D G

D

D

G

H H

D

J E

J

A

F

C

G

C B

A296380

9803/3630

Issue 2*


Section K



4-6

4-6

Preparing the Transmission for Removal


1

Disconnect the parking brake cable B.

2

Disconnect front and rear propshafts at the transmission C.

3

Drain the hydraulic tank.

4

Label and disconnect the pipe and hose connections D to the hydraulic pump.

5

Disconnect the transmission fluid filter hoses H (when fitted). Cap the hoses and pipes to prevent the ingress of dirt.

6

Unclip the electrical cables at J.

7

Undo the transmission oil cooler pipe fixing on the chassis (not shown).

8

Make sure that all the relevant hoses pipes and wiring have been disconnected and tied away from the transmission assembly.

* Removal 1

Attach a specially fabricated lifting beam to engine lifting brackets, as shown at X. Using suitable lifting equipment take the weight of the engine and transmission assembly (approx. 1 Tonne).

Note: The tool (lifting beam) is designed specifically to lift the side mounted engine, bevel box and Powershift transmission as a complete assembly. Refer to Section 1 Service Tools, Section K - Engine, for details of manufacture and conditions of use. This tool is designed specifically to lift the side mounted engine, bevel box and powershift transmission as a complete assembly. The tool is not to be used to lift the engine on its own, any other part of the machine or for any other lifting duty or use. 2

Place suitable engine support stands under the engine at E and gearbox at F.

3

Undo and remove the three transmission mounting bolts G. Make sure that the assembly is safely supported by the lifting equipment and then remove the stands.

4

Lower and withdraw the assembly from the machine.

Replacement Replacement is a reversal of the removal procedure. Adjust the parking brake as required. Replenish oil and water levels on completion. Torque settings Item G

Nm 118

kgf m 12

lbf ft 87

X

A296430

9803/3630

Issue 2*


Section K



5-1

5-1

Separating the Engine and Bevel Box The engine, bevel box and transmission should be removed from the machine as one complete unit before carrying out the following procedure. 1

Remove bell housing bolts N.

Note: The bolts N are sized to suit their positions. Bell housing bolts must be replaced in the same positions. 2

Carefully draw the engine away from the transmission. Be careful not to put any side force on the transmission input shaft. Lift the engine clear of the machine.

Replacement

R

Replacement is the reverse of the removal procedure. If the damper P has been removed, clean the mating faces with a clean, dry cloth. The damper can be fitted in any position as it is balanced individually.

A296480

P

Apply JCB Activator and JCB Threadlocker and Sealer to the 6 bolts R. Torque tighten the 6 bolts R - see Section 1. Apply locking fluid and torque tighten bolts N, making sure the bolts are fitted in the correct position, as marked during removal.

N

Torque settings Item N R

Nm 98 36

kgf m 10 3.7

lbf ft 72 26

9803/3630

S296462

Issue 1


Section K


10 - 1

Fuel Lift Pump


10 - 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.

A

The procedure to remove and fit the new pump has not changed, see Engine Service Manual. Remove and clean fuel inlet strainer 2 when it is suspected that it may be blocked, for example low power, difficult starting, fuel tank contamination.

2 3

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 fuel filter 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. 366611

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.

9803/3630

Issue 1




www.maskinisten.net

jcb_530_533_535_540_sm.pdf

Recommend Documents