JCB 3000 XTRA Series Fastrac Repair Service Manual

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(S/N: 1272000 onwards)

This service manual PDF download for the 3000 XTRA Series JCB Fastrac has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Fastrac 3000 XTRA Series
S/N: 1272000 onwards

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine Maintenance
Section A – Hitches and Attachments
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section S – Suspension
Section T – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9970-01
Total Pages : 725

This JCB Fastrac service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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9803-9970
3000 XTRA Series Fastrac

Section 1
General Information
Use
Introduction
Scope
Personnel
Applications
Newest Data
Format
Left and Right Sides
Hydraulic Schematic Codes
Colour Codes
Machine Identification
Introduction
Identifying your Machine
Machine Identification Plate
Component Identification Plates
ROPS and FOPS Certification Labels
Torque Settings
Introduction
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Service Tools
Numerical List
Tool Detail Reference
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section S – Suspension
Service Consumables
Sealing and Retaining Compounds

Section 2
Care and Safety
Safety First
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
General Procedures
Introduction
Health and Safety
Lubricants
Battery
Parking the Machine and Making it Safe
Releasing the Hydraulic Pressure
Carrying Tools onto the Machine
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Quick Release Couplings
Connecting and Disconnecting
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Battery Disconnection/Connection
Disconnection
Connection
Removing and Replacing Components
Battery Charging System Precautions
Hydraulic Rams
Installation
Caution During Use
Maintenance, Inspection Points

Section 3
Routine Maintenance
Routine Maintenance
Introduction
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection
Obtaining Replacement Parts
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities, Fuel
Coolant Mixtures
Fuel
Cleaning the Machine
Introduction
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Checking the ROPS Structure
Greasing
Introduction
Drive Shafts
Front Axle Steering Swivels
Agricultural Front 3-Point Linkage (Optional)
Steering Column Universal Joints
Rear Suspension Cylinder Pivots
Hydraulic Lift and 3-Point Linkage
Rear PTO Drive Shaft Bearing
Automatic Trailer Coupling (if fitted)
Access Panels
Opening the Engine Cover
Closing the Engine Cover
Air Conditioning and Heater
Air Conditioning Filters
Cleaning the Heater Filter
Brakes
Checking the Foot Brake Fluid Level
Checking the Trailer Air Tank
Checking the Air Tank Warning Lights
Checking and Renewing Foot Brake Pads
Testing the Park Brake
Checking the Park Brake Pads
Electrical
Battery
Jump-starting the Engine
Checking the Beam Alignment
Fuses and Relays
Engine
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Draining and Refilling the Coolant
Fan Belt
Changing the Air Filter Elements
Fuel System
Introduction
Draining the Fuel Pre-Filter
Changing the Fuel Pre-Filter Element
Changing the Fuel Filter Element
Bleeding the Fuel System
Hydraulic System
Introduction
Checking the Fluid Level
Changing the Filter Element
Changing the Hydraulic Fluid and Cleaning the Suction Strainers
Coupling Drains
Transmission
Checking the Transmission Oil Level
Changing the Transmission Oil Filter
Changing the Transmission Oil and Cleaning the Strainer
Front Axle
Rear Axle
Tyres and Wheels
General
Check the Tyres
Tyre Inflation
Wheel Nut Torques
Adjustable Track Width
Lock Stops
Checking and Adjusting the Front Wheel Alignment
Fender Adjustment
Windscreen Washer
Checking Fluid Level
Automatic Trailer Coupling (Optional)
Checking for Wear

SectionA
Hitches and Attachments
Agricultural Front Hitch SYSTEM
Introduction
Operation Overview
Fault Finding
Position Sensor Removal and Replacement
Removal and Replacement
Position Sensor Calibration
Rear Hitch Draft Control SYSTEM
Introduction
Operation Overview
Automatic Draft Control
Fault Finding
Draft Pins Removal and Replacement
Position Sensor Removal and Replacement
Position Sensor Calibration

SectionC
Electrics
Fuses and Relays
Introduction
Relays
Access and Location
Relays at the Rear of the Cab
Relays at the Front of the Cab
Relays at the Side of the Cab
Relays in Engine Compartment
Fuses
Access and Location
Main Fuses
Lighting Fuses
Engine-mounted Fuses
Schematics
Introduction
All Machines
Sheets
Component Keys
Harness SYSTEM
Introduction
Drawings and Interconnection
Harnesses
Drawings
Electronics Network SYSTEM
Introduction
System Overview
Fault Finding
Engine Control ECU
Inputs/Outputs
Removal and Replacement
Dashboard ECU (EMS)
Setup
Inputs/Outputs
Removal and Replacement
Central Control ECU (ECU1)
Inputs/Outputs
Access
Removal and Replacement
Transmission Control ECU (TECU)
Inputs/Outputs
Access
Removal and Replacement
Draft Control ECU (EHR-Z)
Inputs/Outputs
Access
Removal and Replacement
ABS Control ECU
Inputs/Outputs
Access
Removal and Replacement
Auxiliary Controls ECU (ACE)
Inputs/Outputs
Access
Removal and Replacement
Touch Screen ECU (DECU)
Inputs/Outputs
Service Calibration Mode
Engine Throttles Calibration
PTO Speed Selection Calibration
Joystick Calibration
Transmission Calibration
Steering Angle Calibration
Screen Calibration
Access
Removal and Replacement
Ground Radar SYSTEM
Operation Overview
Fault Finding
Calibration
Service Master SYSTEM
Why Use Service Master?
Introduction
Fault Finding
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECUs
Summary
What is Service Master?
Introduction
CANbus Communications System
Service Master Structure
How to Set Up Service Master
Install Service Master
Start Service Master
Load the DLA Laptop Driver Software
Configure the DLA Type and Communications Port
Check the DLA Firmware File
Connect Service Master to the Machine CANbus
Service Master Tools
Summary
3000 Diagnostics Tool – Content Guide
Fault Code SYSTEM
Fault Codes
ABS ECU
Fastrac Central Controller – ECU1
EMS Dashboard
DECU (Touch Screen)
Engine ECU (6.7 QSB)
Rear Hitch
Suspension
Gearbox 6×4
Front Hitch Slice
Green Slice
Blue Slice
Brown Slice
Grey Slice
Battery Charging SYSTEM
Introduction
Technical Data
Electrical Operation and Schematics
Test Procedures
Alternator Charging Test
Battery
Introduction
Specifications
Battery Connections
Access
Maintenance
Battery
Test Procedures
Battery Load Testing
Specific Gravity Testing
Battery Disconnection/Connection
Disconnection
Connection
Removal and Replacement
Removal
Replacement

SectionE
Hydraulics
Schematic Circuits
Introduction
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Complete Machine Circuit with Power Beyond Service
Component Key
External Hydraulics SYSTEM
Introduction
Technical Data
Flow Rates
Pressures
Spool Valve
Other Hydraulic Circuits
Pressure Testing
Maximum System Pressure
Pilot Stand-by Pressure
Power Beyond Operation
Spool Valve SYSTEM
Introduction
Operation Overview
Control Network
Configuration
Calibration
Configuration
Accessing the Configuration Mode
Valve Slices Currently Configured
Configuring `Bosch’ Slices
Calibration – Auxiliary and Hitch Control Parameters
Fault Finding
LED Blink Codes
Removal and Replacement
Dismantle and Assemble
Variable Flow Pump
Introduction
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Control Valve
Sealing the Driveshaft
Pump
Gear Pump (Suspension and Steering)
Dismantling and Assembly
Gear Pump (Suspension and Steering)
Introduction
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Rear Hitch Ram
Introduction
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
Assembly
Testing
Front Hitch Ram
Introduction
Removal and Replacement
Dismantling and Assembly
Dismantling
Assembly
Testing

SectionF
Section F
Section F
Transmission
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Service Manual – 3000 XTRA Series Fastrac
Service Manual – 3000 XTRA Series Fastrac
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
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Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Hitches and Attachments
Section A – Hitches and Attachments
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
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Section G – Brakes
Section G – Brakes
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Section H – Steering
Section H – Steering
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Section S – Suspension
Section S – Suspension
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Section T – Engine
Section T – Engine
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Notes:
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6 x 4 Smoothshift Transmission SYSTEM
6 x 4 Smoothshift Transmission SYSTEM
Introduction
Introduction
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This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system..
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Descriptions and procedures relate to the system and not the individual devices.
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This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
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K Technical Data ( T F1-3)
K Technical Data ( T F1-3)
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K Flow Rate and Pressures ( T F1-3)
K Flow Rate and Pressures ( T F1-3)
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K Transmission Technical Data Checklist ( T F1-4)
K Transmission Technical Data Checklist ( T F1-4)
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K Component Identification ( T F1-6)
K Component Identification ( T F1-6)
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K External Components ( T F1-6)
K External Components ( T F1-6)
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K Internal Components ( T F1-8)
K Internal Components ( T F1-8)
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K Hydraulic Circuit ( T F1-10)
K Hydraulic Circuit ( T F1-10)
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K Electrical and Electronic Network ( T F1-13)
K Electrical and Electronic Network ( T F1-13)
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K Ratio and Drive Control ( T F1-14)
K Ratio and Drive Control ( T F1-14)
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K Joystick Controller ( T F1-14)
K Joystick Controller ( T F1-14)
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K Column Switch ( T F1-14)
K Column Switch ( T F1-14)
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K Touch Screen Control ( T F1-15)
K Touch Screen Control ( T F1-15)
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K Calibration ( T F1-16)
K Calibration ( T F1-16)
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K Master Clutch Control ( T F1-17)
K Master Clutch Control ( T F1-17)
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K Clutch Pedal Position Sensor ( T F1-17)
K Clutch Pedal Position Sensor ( T F1-17)
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K PTO Control ( T F1-18)
K PTO Control ( T F1-18)
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K Speed Change Lever Control ( T F1-18)
K Speed Change Lever Control ( T F1-18)
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K Drive Paths ( T F1-19)
K Drive Paths ( T F1-19)
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K Solenoid Identification ( T F1-19)
K Solenoid Identification ( T F1-19)
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K Clutch Packs – Identification ( T F1-20)
K Clutch Packs – Identification ( T F1-20)
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K Forward/First + High Range ( T F1-22)
K Forward/First + High Range ( T F1-22)
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K Forward/Second + Medium Range ( T F1-24)
K Forward/Second + Medium Range ( T F1-24)
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K Forward/Third + Low Range ( T F1-26)
K Forward/Third + Low Range ( T F1-26)
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K Forward/Fourth + Extra Low Range ( T F1-28)
K Forward/Fourth + Extra Low Range ( T F1-28)
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K Forward/Fifth + Low Range ( T F1-30)
K Forward/Fifth + Low Range ( T F1-30)
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K Forward/Sixth – Medium Range ( T F1-32)
K Forward/Sixth – Medium Range ( T F1-32)
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K Reverse/First – High Range ( T F1-34)
K Reverse/First – High Range ( T F1-34)
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K Fault Finding ( T F1-36)
K Fault Finding ( T F1-36)
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K Complete Transmission ( T F1-36)
K Complete Transmission ( T F1-36)
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K Wet Master Clutch ( T F1-37)
K Wet Master Clutch ( T F1-37)
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K Power Take Off Clutches ( T F1-39)
K Power Take Off Clutches ( T F1-39)
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K 4/2 Wheel Drive ( T F1-40)
K 4/2 Wheel Drive ( T F1-40)
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K Test Procedures ( T F1-41)
K Test Procedures ( T F1-41)
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K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
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Technical Data
Technical Data
Flow Rate and Pressures
Flow Rate and Pressures
The following figures are measured with the transmission oil at operating temperature.
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Transmission Charge Pump
Litres/min
UK Gal/min
US Gal/min
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Maximum flow rate @ 2200 engine rev/min
67 – 71
14.7 – 15.6
17.7 – 18.8
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Transmission Pressures
Engine rev/min
bar
lbf/in2
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Main Line Pressure
800
12.4 – 13.8
180- 200
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1600
13.1 – 14.5
190 – 210
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2200
13.1 – 14.5
190 – 210
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Lubrication Pressure
800
0 – 0.1
0 – 1.5
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2200
1 – 2
14.5 – 2.9
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Wet Clutch High Pressure Lubrication
800
2.7
39
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2200
10
145
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Wet Master Clutch Operating Pressure
800
Mainline less 0.7
Mainline less 10
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Clutch A Operating Pressure
1600
Mainline less 0.7
Mainline less 10
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Clutch B Operating Pressure
1600
Mainline less 0.7
Mainline less 10
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Clutch C Operating Pressure
1600
Mainline less 0.7
Mainline less 10
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Clutch D Operating Pressure
1600
Mainline less 0.7
Mainline less 10
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Clutch E Operating Pressure
1600
Mainline less 0.7
Mainline less 10
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Clutch R Operating Pressure
1600
Mainline less 0.7
Mainline less 10
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High Range Selector Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Medium Range Selector Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Low Range Selector Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Extra Low Range Selector Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Four Wheel Drive Disconnect Operating Pressure
1600
Mainline less 0.5
Mainline less 7
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Front Power Take Off Brake Release Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Rear Power Take Off Brake Release Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Front Power Take Off Clutch Operating Pressure
1600
Mainline less 0.5
Mainline less 7
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Rear Power Take Off Clutch Operating Pressure
1600
Mainline less 0.5
Mainline less 7
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Transmission Brake Operating Pressure
800
Mainline less 0.5
Mainline less 7
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Differential Lock Operating Pressure
25
360
Transmission Technical Data Checklist
Transmission Technical Data Checklist
Reference Data
Reference Data
The following Technical Data Checklist introduced by JCB Transmissions is available from the Technical Service Team and should b…
Correct completion of the checklist will assist the engineer in diagnosing gearbox/transmission abnormalities.
Completed Checklists may then be saved as required and if necessary forwarded to the Technical Service Team for further assistance via email or preferably a Techweb call.
In the event of a complete transmission replacement under warranty (due to performance related issues), the dealer is expected t…
For safety the procedures detailed in the Service Manual MUST be followed.
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Transmission Technical Data Checklist
Transmission Technical Data Checklist
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Company
Contact Name
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Transmission Serial Number
Email Address/Tel. Number
/
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Machine Make/Model
Installation Date
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Machine Serial Number
Machine Hours
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Oil Used
Oil Sample
Yes ………………No……………
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1. Pressures at 500C
0
1000 Rev/min
2000 Rev/min
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Wet Clutch In
Test Point 3
3
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Wet Clutch Lubrication
Test Point 14
14
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Mainline
Test Point 1
1
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Lubrication
Test Point 2
2
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High Range
Test Point 8
8
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Medium Range
Test Point 9
9
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Low Range
Test Point 10
10
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Extra Low Range
Test Point 11
11
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Clutch A
A
Test Point 15
15
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Clutch B
B
Test Point 4
4
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Clutch C
C
Test Point 6
6
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Clutch D
D
Test Point 5
5
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Clutch E
E
Test Point 7
7
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Clutch R
R
Test Point 17
17
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4 WD Disconnect
Test Point 12
12
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Front PTO Brake Release
Test Point 16
16
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Rear PTO Brake Release
Test Point 18
18
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Front PTO Clutch
Test Point 19
19
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Rear PTO Clutch
Test Point 21
21
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Trans Brake Release
Test Point 20
20
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2. Transmission Flow Testing at 500C
0
l/min in Neutral at 1000 Rev/min
Gal/min in Neutral at 2000 Rev/min
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Measured at pump outlet
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3. Summary of Symptoms / Fault / Previous History
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Signature
Date
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Component Identification
Component Identification
External Components
External Components
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K Fig 1. ( T F1-7)
K Fig 1. ( T F1-7)
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1
1
Wet clutch casing
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2
2
Rear casing
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3
3
Intermediate casing
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4
4
Front casing
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5
5
Range box casings
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6
6
Front P.T.O. assembly
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7
7
Rear P.T.O. assembly
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8
8
Park brake disc and rear axle driveshaft coupling
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9
9
Charge pump
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10
10
Solenoid control valve block
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11
11
P.T.O. ratio position sensor
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12
12
Front axle driveshaft coupling
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13
13
Speed sensors
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14
14
Range box selector position sensors
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15
15
Range box selector solenoid control valves
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16
16
Pump drive interface
<GRAPHIC
<GRAPHIC
C090310
Fig 1. External Components
Internal Components
Internal Components
The component locations shown are different to actual locations in the gearbox. The illustrations identify the main components a…
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K Fig 2. ( T F1-9)
K Fig 2. ( T F1-9)
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1
1
Wet clutch casing
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2
2
Rear casing
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3
3
Intermediate casing
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4
4
Front casing
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5
5
Range box casings
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6
6
Wet clutch assembly
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7
7
P.T.O. input shaft (engine driven)
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8
8
Centre bearing shaft
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9
9
Mainshaft
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10
10
Range box mainshaft
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11
11
Range box output shaft
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14
14
P.T.O. idler shaft
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15
15
P.T.O. ration selector shaft
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16
16
Rear P.T.O. clutch
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17
17
P.T.O. intermediate gear shaft
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18
18
P.T.O. selector rail and fork
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19
19
Pump drive shaft
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20
20
Transmission brake assembly
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37
37
Wet clutch driven gear
<TABLE ROW
39
Idler shaft and gear
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A
A
Ratio clutch pack A
A
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B
B
Ratio clutch pack B
B
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C
C
Ratio clutch pack C
C
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D
D
Ratio clutch pack D
D
<TABLE ROW
E
E
Ratio clutch pack E
E
<TABLE ROW
R
R
Reverse clutch pack R
R
<TABLE ROW
S
S
Four wheel drive de-selector clutch pack
<GRAPHIC
<GRAPHIC
C090320
Fig 2. Internal Components
Hydraulic Circuit
Hydraulic Circuit
This JCB Smoothshift full power shifting transmission is made up of three distinct assemblies.
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1
Wet Clutch Assembly
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2
Smoothshift Gearbox Assembly, incorporating Splitter Box and independent drive to Front and Rear Power Take Off drives.
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3
Range Box Assembly
All three assemblies are hydraulically supplied by charge pump
4
5
Pump
4
6
7
8
Pump delivery flows via external hoses and pipework first to oil cooler
8
9
There are two sensors fitted in this area. Temperature sensor
30
31
Cooled and filtered pump delivery enters control valve
6
32
1
12
Downstream of sensor
32
10
1
As pump supply pressure rises, it is sensed through filtered pilot line controlling sequence valve
10
6
3
Pressurised flow to control valve is tee’d off to fill the pressure accumulator
11
The selection of the clutch packs in Smoothshift gearbox
2
13
14
15
16
17
18
19
22
2
3
L
G
H
25
26
27
28
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Item
Component
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4
Transmission Pump
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5
Suction Strainer
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6
Selector Valve
<TABLE ROW
7
By-pass Valve
<TABLE ROW
8
Oil Cooler
<TABLE ROW
9
Oil Filter
<TABLE ROW
10
Pressure Maintenance Sequencing Valve
<TABLE ROW
11
Pressure Accumulator
<TABLE ROW
12
Wet Master Clutch Lubrication Solenoid
<TABLE ROW
13
Clutch A Solenoid
<TABLE ROW
14
Clutch B Solenoid
<TABLE ROW
15
Clutch C Solenoid
<TABLE ROW
16
Clutch D Solenoid
<TABLE ROW
17
Clutch E Solenoid
<TABLE ROW
18
Reverse Clutch Solenoid
<TABLE ROW
19
Wet Master Clutch Solenoid
<TABLE ROW
20
Front Power Take Off Brake Solenoid
<TABLE ROW
21
Rear Power Take Off Brake Solenoid
<TABLE ROW
22
Front Power Take Off Solenoid
<TABLE ROW
23
Rear Power Take Off Solenoid
<TABLE ROW
24
Transmission Input Brake Solenoid
<TABLE ROW
25
Extra Low Range Solenoid
<TABLE ROW
26
Low Range Solenoid
<TABLE ROW
27
Medium Range Solenoid
<TABLE ROW
28
High Range Solenoid
<TABLE ROW
29
Four Wheel Drive Clutch Solenoid
<TABLE ROW
30
30
Temperature Sensor
<TABLE ROW
31
31
Filter Condition Sensor
<TABLE ROW
32
32
Low Pressure Lubrication Warning Sensor
<TABLE ROW
33
33
Pump Delivery Pressure Sensor
<TABLE ROW
34
34
PTO Ratio Sensor
<TABLE ROW
35
35
Medium/High Range Sensor
<TABLE ROW
36
36
Low/Extra Low Range Sensor
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Transmission Clutches/Brakes
<TABLE BODY
<TABLE ROW
A
Clutch A
<TABLE ROW
B
Clutch B
<TABLE ROW
C
Clutch C
<TABLE ROW
D
Clutch D
<TABLE ROW
E
Clutch E
<TABLE ROW
R
Reverse Clutch
<TABLE ROW
F
Wet Master Clutch
<TABLE ROW
G
Front Power Take Off Brake
<TABLE ROW
H
Rear Power Take Off Brake
<TABLE ROW
J
Front Power Take Off Clutch
<TABLE ROW
K
Rear Power Take Off Clutch
<TABLE ROW
L
Transmission Input Brake
<TABLE ROW
M
Extra Low Range Selector Rail Piston
<TABLE ROW
N
Low Range Selector Rail Piston
<TABLE ROW
P
Medium Range Selector Rail Piston
<TABLE ROW
Q
High Range Selector Rail Piston
<TABLE ROW
S
Four Wheel Drive Clutch
The Smoothshift transmission ratios are achieved by the following clutch pack selection combinations.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Forward
Reverse
<TABLE ROW
Ratio
Clutches Selected
Ratio
Clutches Selected
<TABLE BODY
<TABLE ROW
1st
A and C
1st
R and C
<TABLE ROW
2nd
B and C
2nd
R and D
<TABLE ROW
3rd
A and D
3rd
R and E
<TABLE ROW
4th
B and D
<TABLE ROW
5th
A and E
<TABLE ROW
6th
B and E
<GRAPHIC
<GRAPHIC
Fig 3.
Electrical and Electronic Network
Electrical and Electronic Network
TBA
Ratio and Drive Control
Ratio and Drive Control
Joystick Controller
Joystick Controller
<GRAPHIC
<GRAPHIC
C096130
Fig 4.
The joystick contoller moves in two axis and controls the transmission drive mode and gear selection. The buttons on the joystick are programmable.
K Touch Screen Control ( T F1-15)
Removal and Replacement
Removal and Replacement
The joystick is a rugged component. Before replaceing the unit do the fault finding procedures. Use JCB Service Master. Make sure that the connected devices, wires and connectors are not faulty.
Removal
Removal
1 Park the machine and make it safe. Disconnect the batteries.
1 Park the machine and make it safe. Disconnect the batteries.
2 Pull up the bottom of gaiter
1
3 Undo four screws
2
4 Lift out the joystick and uncouple its electrical connectors.
Replacement
Replacement
Replacement is the opposite of the removal procedure.
After installation of a new joystick controller do the following:
– Calibrate the movement of the joystick. Use the touch screen, (see
– Calibrate the movement of the joystick. Use the touch screen, (see
Section C – Electronic Network SYSTEM
Column Switch
Column Switch
TBA
Touch Screen Control
Touch Screen Control
<GRAPHIC
<GRAPHIC
C071210-B4
Fig 5.
The touch screen (DECU) enables the operator to select a transmission drive mode (see the
Operator Handbook
<GRAPHIC
<GRAPHIC
C039840-B1
Fig 6.
The touch screen also enables programing of the joystick buttons for operation of transmission modes (see the
Operator Handbook
Calibration
Calibration
The transmission electronic control system calibration ensures correct operation of drive and ratio selection. Calibration is necessary after replacement of any of the following transmission related items:
– Transmission ECU
– Transmission ECU
– Wiring
– Control valves
– Position sensors
– Speed sensors
Use the touch screen to do the calibration procedure, (see
Section C – Electronics Network SYSTEM
Master Clutch Control
Master Clutch Control
<GRAPHIC
<GRAPHIC
C056110-C1
Fig 7.
Proportional solenoid control valve
2
1
Clutch Pedal Position Sensor
Clutch Pedal Position Sensor
<GRAPHIC
<GRAPHIC
C097000
Fig 8.
The transmission ECU gets an input from clutch pedal position potentiometer
A
The transmission must be calibrated after installation or adjustment of the sensor
A
Section C – Electronics Network SYSTEM
PTO Control
PTO Control
The gearbox front and rear power take off clutches are engaged electrically by switches in the cab and on the outside of the machine.
Speed Change Lever Control
Speed Change Lever Control
<GRAPHIC
<GRAPHIC
C096990
Fig 9.
The speed control lever
1
When the lever moves to select high speed metal lever arm
2
3
4
Control cable
5
2
6
The switches
3
4
5
Section C – Electronics Network SYSTEM
Drive Paths
Drive Paths
Solenoid Identification
Solenoid Identification
The annotations identifying the selector solenoids are the same as detailed on the Transmission Hydraulic Circuit Description as follows.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Solenoid
Solenoid Description
<TABLE BODY
<TABLE ROW
13
13
Clutch A Solenoid
<TABLE ROW
14
14
Clutch B Solenoid
<TABLE ROW
15
15
Clutch C Solenoid
<TABLE ROW
16
16
Clutch D Solenoid
<TABLE ROW
17
17
Clutch E Solenoid
<TABLE ROW
18
18
Reverse Clutch Solenoid
<TABLE ROW
19
19
Wet Master Clutch Solenoid
<TABLE ROW
20
20
Front P.T.O. Brake Solenoid
<TABLE ROW
21
21
Rear P.T.O. Brake Solenoid
<TABLE ROW
22
22
Front P.T.O. Solenoid
<TABLE ROW
23
23
Rear P.T.O. Solenoid
<TABLE ROW
24
24
Transmission Brake Solenoid
The Smoothshift transmission ratios are achieved by the following solenoid selection combinations.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Forward
Reverse
<TABLE ROW
Ratio
Solenoids Selected
Ratio
Solenoids Selected
<TABLE BODY
<TABLE ROW
1st
13 and 15
1st
18 and 15
<TABLE ROW
2nd
14 and 15
15
2nd
18 and 16
<TABLE ROW
3rd
13 and 16
3rd
18 and 17
<TABLE ROW
4th
14 and 16
<TABLE ROW
5th
13 and 17
<TABLE ROW
6th
14 and 17
If selector valves
13
24
<GRAPHIC
<GRAPHIC
C056110
Fig 10.
Clutch Packs – Identification
Clutch Packs – Identification
The following illustrations showing clutch pack identification and range/ratio power flows have the shafts illustrated to easily…
39
37
<GRAPHIC
<GRAPHIC
C057310
Fig 11.
The illustration shows a more accurate shaft orientation viewed from the front Wet Clutch end of the transmission, as can be seen shaft
38
37
37
39
43,
56
40
47
K Fig 11. ( T F1-20)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
37
37
Input Shaft Gear
<TABLE ROW
38
38
Clutch R support shaft
R
<TABLE ROW
39
39
Idler Shaft
<TABLE ROW
40
40
Clutch A support shaft
A
<TABLE ROW
43
43
Free to spin Clutch A drive gear
A
<TABLE ROW
47
47
Clutch B/C support shaft
B
C
<TABLE ROW
56
56
Free to spin Clutch B drive gear
B
<TABLE ROW
A
A
Ratio Clutch Pack A
A
<TABLE ROW
B
B
Ratio Clutch Pack B
B
<TABLE ROW
C
C
Ratio Clutch Pack C
C
<TABLE ROW
D
D
Ratio Clutch Pack D
D
<TABLE ROW
E
E
Ratio Clutch Pack E
E
<TABLE ROW
R
R
Reverse Clutch Pack R
R
<TABLE ROW
S
S
Four Wheel Drive De-selector Clutch Pack
<GRAPHIC
<GRAPHIC
C057280
Fig 12.
Forward/First + High Range
Forward/First + High Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
R
38
Power is transmitted via Idler gear
39
43
40
A
D
<GRAPHIC
<GRAPHIC
C056110
Fig 13.
The operator has selected forward first on the control panel which has energised proportional solenoid valves
13
15
6
41
42
A
C
As soon as clutch
A
43
40
44
D
44
45
46
47
48
42
C
47
48
48
49
50
<GRAPHIC
<GRAPHIC
C057300
Fig 14.
With High Range direct acting solenoid
28
52
53
54
55
Also identified are range box solenoids numbered
25
26
27
28
29
<GRAPHIC
<GRAPHIC
C057280-C1
Fig 15.
Forward/Second + Medium Range
Forward/Second + Medium Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
2
R
38
Power is transmitted via Idler gear
39
56.
<GRAPHIC
<GRAPHIC
Fig 16.
The operator has selected forward second on the control panel which has energised proportional solenoid valves
14
15
42
57
B
C
As soon as clutch
B
56
47
C
C
48
47
48
49
64
50
51
3
<GRAPHIC
<GRAPHIC
C057300
Fig 17.
With Medium Range direct acting solenoid
27
52
58
54
55
<GRAPHIC
<GRAPHIC
C057280-C2
Fig 18.
Forward/Third + Low Range
Forward/Third + Low Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
2
R
38
Power is transmitted via Idler gear
39
59
40
A
D
<GRAPHIC
<GRAPHIC
C056110
Fig 19.
The operator has selected forward third on the control panel which has energised proportional solenoid valves
13
16
60
61
As soon as clutch
A
59
40
62
D
D
63
63
64
49
50
51
3
<GRAPHIC
<GRAPHIC
C057300
Fig 20.
With Medium/High Range direct acting solenoids
27
28
52
26
65
67
54
66
67
55
<GRAPHIC
<GRAPHIC
C05728-C3
Fig 21.
Forward/Fourth + Extra Low Range
Forward/Fourth + Extra Low Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
2
R
38
Power is transmitted via Idler gear
39
56
47
B
C
<GRAPHIC
<GRAPHIC
C056110
Fig 22.
The operator has selected forward fourth on the control panel which has energised proportional solenoid valves
14
16
57
61
As soon as clutch
B
56
47
47
C
46
45
44
44
D
63
63
64
50
51
3
<GRAPHIC
<GRAPHIC
C057300
Fig 23.
With Medium/High Range direct acting solenoids
27
28
52
26
65
68
69
55
<GRAPHIC
<GRAPHIC
C057280-C4
Fig 24.
Forward/Fifth + Low Range
Forward/Fifth + Low Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
2
R
38
Power is transmitted via Idler gear
39
59
40
A
D
<GRAPHIC
<GRAPHIC
C056110
Fig 25.
The operator has selected forward fifth on the control panel which has energised proportional solenoid valves
13
17
60
70
A
E
As soon as clutch
A
59
40
62
D
D
63
44
45
71
70
71
64
50
51
3
<GRAPHIC
<GRAPHIC
C057300
Fig 26.
With High/Medium range direct acting solenoids
27
28
52
26
65
66
67
67
54
55
<GRAPHIC
<GRAPHIC
C057280-C5
Fig 27.
Forward/Sixth – Medium Range
Forward/Sixth – Medium Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
2
R
38
Power is transmitted via Idler gear
39
56
47
B
C
<GRAPHIC
<GRAPHIC
C056110
Fig 28.
The operator has selected forward sixth on the control panel which has energised proportional solenoid valves
14
17
57
70
B
E
As soon as clutch
B
56
47
46
45
E
45
64
50
51
3
<GRAPHIC
<GRAPHIC
C057300
Fig 29.
With Medium range direct acting solenoid
27
52
58
59
55
<GRAPHIC
<GRAPHIC
C057280-C6
Fig 30.
Reverse/First – High Range
Reverse/First – High Range
Description
Description
Engine power and torque has been transmitted via the Wet Clutch assembly
1
37
2
R
38
Power is transmitted via Idler gear
39
56
47
B
C
<GRAPHIC
<GRAPHIC
C056110
Fig 31.
The operator has selected Reverse first on the control panel which has energised proportional solenoid valves
18
15
72
42
R
C
As soon as clutch
R
37
38
73
45
46
47
C
C
48
49
50
51
3
<GRAPHIC
<GRAPHIC
C057300
Fig 32.
With High range direct acting solenoid
28
52
53
54
55
<GRAPHIC
<GRAPHIC
C057280-C7
Fig 33.
Fault Finding
Fault Finding
Complete Transmission
Complete Transmission
Table 1.
Table 1.
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Has the tractor software just been reprogrammed?
Make sure the correct software has been used.
<TABLE ROW
<TABLE ROW
2
Does the touch screen (DECU) show a gear and direction selected?
<TABLE ROW
<TABLE ROW
3
Check all transmission ECU fuses.
<TABLE ROW
<TABLE ROW
4
Check the powershift dump relay.
<TABLE ROW
<TABLE ROW
5
Check for tractor error codes.
Download datalog.
<TABLE ROW
<TABLE ROW
6
Monitor the clutch pedal position (%) and activation switch using Service Master or the DECU Information.
Recalibrate if necessary.
<TABLE ROW
<TABLE ROW
7
Using Service Master, check that the selected powershift solenoids are energised.
<TABLE ROW
<TABLE ROW
8
Using Service Master, monitor the selected range gear and rail position (%).
<TABLE ROW
<TABLE ROW
9
Using Service Master, monitor the transmission intermediate and output speed sensors.
<TABLE ROW
<TABLE ROW
10
Check transmission oil level and oil grade are correct.
<TABLE ROW
<TABLE ROW
11
Check that mainline oil pressure is correct. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
<TABLE ROW
12
Check the relevant wet clutch, powershift and range oil pressures. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
<TABLE ROW
13
Do axle drive shafts rotate when a gear is selected? (Test with 4WD selected.)
Isolate mechanical components and investigate.
Wet Master Clutch
Wet Master Clutch
Clutch fails to engage, slips or engages erratically:
Clutch fails to engage, slips or engages erratically:
Table 2.
Table 2.
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Check for active fault codes using Service Master.
Download datalog.
<TABLE ROW
<TABLE ROW
2
Monitor the clutch pedal position (%) and activation switch using Service Master.
Recalibrate if necessary.
<TABLE ROW
<TABLE ROW
3
Monitor the wet clutch solenoid current using Service Master.
<TABLE ROW
<TABLE ROW
4
Check transmission oil level and oil grade are correct.
<TABLE ROW
<TABLE ROW
5
Check that mainline oil pressure is correct.K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
<TABLE ROW
6
Check the wet clutch pressure. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
Clutch fails to disengage correctly when machine is in motion:
Clutch fails to disengage correctly when machine is in motion:
Table 3.
Table 3.
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Check for active fault codes using Service Master.
Download datalog.
<TABLE ROW
<TABLE ROW
2
Monitor the clutch pedal position (%) and activation switch using Service Master.
Recalibrate if necessary.
<TABLE ROW
<TABLE ROW
3
Check that powershift dump relay is energised when clutch pedal is fully down.
Renew the potentiometer.
<TABLE ROW
<TABLE ROW
4
Recalibrate the gearbox.
<TABLE ROW
<TABLE ROW
5
Check that mainline oil pressure is correct. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
<TABLE ROW
6
Check the wet clutch pressure. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
<TABLE ROW
The following checks can only be carried out after the complete gearbox assembly has been removed from the machine. Make sure that all other checks have been carried out correctly before contemplating removal of the gearbox.
<TABLE ROW
7
Is the clutch piston check valve faulty?
Renew the check valve.
<TABLE ROW
8
Are steps visible in the drive tangs on the clutch drum?
Renovate or renew the drum as required.
<TABLE ROW
9
Are the clutch return springs worn or broken?
Renew the springs.
<TABLE ROW
Always renew the springs even if they appear serviceable.
Power Take Off Clutches
Power Take Off Clutches
PTO Clutch does not engage:
PTO Clutch does not engage:
Table 4.
Table 4.
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Check the operator settings for PTO cutout such as linkage height settings, which will prevent the PTO from engaging (flashing PTO icon).
<TABLE ROW
<TABLE ROW
2
Check for active fault codes.
Download datalog.
<TABLE ROW
<TABLE ROW
3
Is the PTO speed selector fully engaged?
Monitor the selector values in the gearbox using Service Master.
<TABLE ROW
<TABLE ROW
4
Monitor the PTO On/off switch in the cab using Service Master.
<TABLE ROW
<TABLE ROW
5
Monitor the external PTO cut-out switch using Service Master. (A fault will prevent PTO start-up.)
<TABLE ROW
<TABLE ROW
6
If 2WD cannot be selected, check the relevant fuses.
<TABLE ROW
<TABLE ROW
7
Monitor the PTO clutch solenoid being energised using Service Master.
<TABLE ROW
<TABLE ROW
8
Check the PTO clutch solenoid is actually being energised.
<TABLE ROW
<TABLE ROW
9
Measure the PTO clutch oil pressure. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
<TABLE ROW
<TABLE ROW
10
Check the correct PTO option is set using the Set-up Tool (Service Master).
<TABLE ROW
<TABLE ROW
11
Check for mechanical drive line failure in the PTO system.
<TABLE ROW
<TABLE ROW
12
Recalibrate the transmission. (This also calibrates the PTO speed selector position.)
The PTO brake will not affect PTO clutch operation.
PTO continues to rotate when the PTO switch is at stop
PTO continues to rotate when the PTO switch is at stop
The PTO brake is applied 5 seconds after the PTO is switched off.
The PTO brake is low power – it prevents the PTO from rotating when not the PTO is not engaged. It is much less powerful than the PTO clutch and will not affect heavy inertia PTO implements during run down.
Table 5.
Table 5.
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Check for active fault codes.
Download datalog.
<TABLE ROW
<TABLE ROW
2
Monitor the PTO switch position and PTO solenoid state using Service Master.
<TABLE ROW
<TABLE ROW
3
Check the brake solenoid is being energised after 5 seconds.
<TABLE ROW
<TABLE ROW
4
Check the supply fuses are correct.
<TABLE ROW
<TABLE ROW
5
Check the solenoid for faults or internal spool sticking
<TABLE ROW
<TABLE ROW
6
Strip and inspect the pto brake friction plates.
4/2 Wheel Drive
4/2 Wheel Drive
Table 6.
Table 6.
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Check for operator cut-out settings which will prevent 4WD engaging (such as speed, linkage height or steer angle).
<TABLE ROW
<TABLE ROW
2
Check for tractor fault codes.
Download datalog.
<TABLE ROW
<TABLE ROW
3
Monitor 4WD switch and 4WD solenoid using Service Master.
<TABLE ROW
<TABLE ROW
4
Check if the 4WD solenoid is actually energised. (Solenoid on = 4WD.)
<TABLE ROW
<TABLE ROW
5
Check for mechanical 4WD driveline faults.
<TABLE ROW
<TABLE ROW
6
Check 4WD operating pressure. K Gearbox Pressure Test Procedure ( T F1-42)
K Gearbox Pressure Test Procedure ( T F1-42)
Test Procedures
Test Procedures
Prior to pressure testing, transmission fluid levels should be checked and adjusted. (See
Section 3
A
B
<GRAPHIC
<GRAPHIC
C057350
Fig 34.
Gearbox Pressure Test Procedure
Gearbox Pressure Test Procedure
Operate machine to correct transmission operating temperature.
When pressure gauge
C
1 – 12
The following illustrations identify the microbore connections at the transmission and also the self seal couplings which may be used to check pressures controlling other transmission functions.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Item No
Pressure Measured
<TABLE BODY
<TABLE ROW
1
1
Mainline Pressure
<TABLE ROW
2
2
Lubrication Pressure
<TABLE ROW
3
3
Wet Clutch Operating Pressure
<TABLE ROW
4
4
Clutch B Operating Pressure
<TABLE ROW
5
5
Clutch C Operating Pressure
<TABLE ROW
6
6
Clutch D Operating Pressure
<TABLE ROW
7
7
Clutch E Operating Pressure
<TABLE ROW
8
8
High Range Selector Operating Pressure
<TABLE ROW
9
9
Medium Range Selector Operating Pressure
<TABLE ROW
10
10
Low Range Selector Operating Pressure
<TABLE ROW
11
11
Extra Low Range Selector Operating Pressure
<TABLE ROW
12
12
Four Wheel Drive Disconnect Clutch Operating Pressure
<TABLE ROW
13
13
Rear Valve Block Pressures, see Section E
Section E
<TABLE ROW
14
14
Wet Clutch High Pressure Lubrication
<TABLE ROW
15
15
Clutch A Operating Pressure
<TABLE ROW
16
16
Front PTO Brake Release Operating Pressure
<TABLE ROW
17
17
Clutch R Operating Pressure
<TABLE ROW
18
18
Rear PTO Brake Release Operating Pressure
<TABLE ROW
19
19
Front PTO Clutch Operating Pressure
<TABLE ROW
20
20
Transmission Brake Release Operating Pressure
<TABLE ROW
21
21
Rear PTO Clutch Operating Pressure
Mainline Pressure
Mainline Pressure
Position 0-40 bar (0-600 lbf/in
2
G
1
Compare recorded pressures with the figures in
Technical Data
Lubrication Pressure
Lubrication Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
2
Compare recorded pressures with the figures in
Technical Data
<GRAPHIC
<GRAPHIC
C057320
Fig 35.
Wet Master Clutch – Operating Pressure
Wet Master Clutch – Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
3
Compare recorded pressures with the figures in Technical Data Section.
Clutch B Operating Pressure
Clutch B Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
4
B
B
C
Compare recorded pressures with the figures in
Technical Data
<GRAPHIC
<GRAPHIC
C057330
Fig 36.
Clutch C Operating Pressure
Clutch C Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
5
C
B
C
Compare recorded pressures with the figures in
Technical Dat
Clutch D Operating Pressure
Clutch D Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
6
A
D
To monitor pressure in clutch
A
G
G
15
Compare recorded pressures with the figures in
Technical Data
Clutch E Operating Pressure
Clutch E Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
7
E
A
D
Compare recorded pressures with the figures in
Technical Data
Clutch R Operating Pressure
Clutch R Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
17
R
R
C
Compare recorded pressures with the figures in
Technical Data
High Range Selector Piston – Operating Pressure
High Range Selector Piston – Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
8
A
D
Compare recorded pressures with the figures in
Technical Data
<GRAPHIC
<GRAPHIC
C057360
Fig 37.
Medium Range Selector Piston – Operating Pressure
Medium Range Selector Piston – Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
9
A
D
Compare recorded pressures with the figures in
Technical Data
Low Range Selector Piston – Operating Pressure
Low Range Selector Piston – Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
10
A
D
Compare recorded pressures with the figures in
Technical Data
Extra Low Range Selector Piston – Operating Pressure
Extra Low Range Selector Piston – Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
12
A
D
Compare recorded pressures with the figures in
Technical Data
Four Wheel Drive Disconnect Clutch
Four Wheel Drive Disconnect Clutch
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
12
B
E
Compare recorded pressures with the figures in
Technical Data
Wet Clutch High Pressure Lubrication
Wet Clutch High Pressure Lubrication
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
14
Compare recorded pressures with the figures in
Technical Data
<GRAPHIC
<GRAPHIC
C057330
Fig 38.
Forward Power Take Off Brake Operating Pressure
Forward Power Take Off Brake Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
16
Compare recorded pressures with the figures in
Technical Data
Rear Power Take Off Brake Operating Pressure
Rear Power Take Off Brake Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
18
Compare recorded pressures with the figures in
Technical Data
Front Power Take Off Clutch Operating Pressure
Front Power Take Off Clutch Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
19
Compare recorded pressures with the figures in
Technical Data
Transmission Brake Operating Pressure
Transmission Brake Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
20
Compare recorded pressures with the figures in
Technical Data
Rear Power Take Off Clutch Operating Pressure
Rear Power Take Off Clutch Operating Pressure
Stop engine and move 0-40 bar (0-600 lbf/in
2
G
21
Compare recorded pressures with the figures in
Technical Data
6 x 4 Smoothshift Gearbox
6 x 4 Smoothshift Gearbox
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the relevant topics.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Charge Pump ( T F2-2)
K Charge Pump ( T F2-2)
<TABLE ROW
K Removal ( T F2-2)
K Removal ( T F2-2)
<TABLE ROW
K Replacement ( T F2-2)
K Replacement ( T F2-2)
<TABLE ROW
K Dismantling ( T F2-3)
K Dismantling ( T F2-3)
<TABLE ROW
K Control Valve ( T F2-4)
K Control Valve ( T F2-4)
<TABLE ROW
K Removal ( T F2-4)
K Removal ( T F2-4)
<TABLE ROW
K Replacement ( T F2-4)
K Replacement ( T F2-4)
<TABLE ROW
K P.T.O. Position Sensors ( T F2-5)
K P.T.O. Position Sensors ( T F2-5)
<TABLE ROW
K Removal ( T F2-5)
K Removal ( T F2-5)
<TABLE ROW
K Replacement ( T F2-6)
K Replacement ( T F2-6)
<TABLE ROW
K Dismantling and Assembly ( T F2-7)
K Dismantling and Assembly ( T F2-7)
<TABLE ROW
K Gearbox ( T F2-9)
K Gearbox ( T F2-9)
<TABLE ROW
K Removal ( T F2-5)
K Removal ( T F2-5)
<TABLE ROW
K Replacement ( T F2-6)
K Replacement ( T F2-6)
<TABLE ROW
K Dismantling and Assembly ( T F2-7)
K Dismantling and Assembly ( T F2-7)
Charge Pump
Charge Pump
Removal
Removal
The numerical sequence is a guide to removal, for replacement the sequence should be reversed.
The transmission pump may be removed with the transmission in situ.
Ensure transmission has been drained of oil and if removed from machine, is securely mounted on manipulator.
1 Disconnect pressure feed hose
1 Disconnect pressure feed hose
1
<GRAPHIC
<GRAPHIC
C066140-C1
Fig 1.
2 Remove capscrews
2
3
3 Collect and discard ‘O’ ring seals
4
Replacement
Replacement
Replacement is a reverse of removal with the following precautions.
1 Renew ‘O’ ring seals
1 Renew ‘O’ ring seals
4
3
2 With the pump casing spigot located in aperture in transmission casing, it may be necessary to carefully shock load pump with a plastic mallet to fully engage spigot.
3 Retain pump with washers and capscrews
2
Dismantling
Dismantling
The numerical sequence is a guide to dismantling. For assembly the sequence may be reversed.
1 Grip the pump body in a vice fitted with soft jaws.
1 Grip the pump body in a vice fitted with soft jaws.
2 Undo capscrews
1
3 Lift cover
2
3
4
5
6
4 Press gear shaft
7
8
8
5 Lift pump rotor
10
11
6 Release large circlip
12
13
<GRAPHIC
<GRAPHIC
Fig 2.
Control Valve
Control Valve
Removal
Removal
The numerical sequence is a guide to removal, for replacement the sequence should be reversed.
Prior to removal pressure wash dirt and debris from the external casings of the transmission. Be sure to protect electrical and hydraulic connections from any chemicals used in the wash equipment.
1 Disconnect wiring connectors from each of the solenoid selector valves
1 Disconnect wiring connectors from each of the solenoid selector valves
1
2 Disconnect hydraulic hose
2
3 The illustration shows self seal pressure testing points
3
When releasing fixing screws
6
4 It is recommended that bolts
3
4
5 Remove and discard gasket between valve block and transmission casing.
<GRAPHIC
<GRAPHIC
C066250
Fig 3.
Replacement
Replacement
Replacement is a reverse of removal with the following precautions.
– Position new gasket over support studs left in casing.
– Position new gasket over support studs left in casing.
– Offer valve block to transmission over studs in position
3
4
3
4
– Reconnect hydraulic hoses
2
– On completion use the touch screen to calibrate the transmission , see
Section C – Electronics Network SYSTEM
P.T.O. Position Sensors
P.T.O. Position Sensors
The front and rear P.T.O. position sensors record the position of the P.T.O. selector rail and is located underneath the Smoothshift gearbox casing at
A
<GRAPHIC
<GRAPHIC
C057250
Fig 4.
Removal
Removal
If position sensors are renewed then a full recalibration must be performed on transmission.
The numerical sequence is a guide to removal.
Replacement
Replacement
<GRAPHIC
<GRAPHIC
C055290-C1
Fig 5.
Offer electric sensor body
2
2
E
D
1
On completion do the PTO calibration procedure, use the touch screen, see
Section C – Electronics Network SYSTEM
Dismantling and Assembly
Dismantling and Assembly
The numerical sequence is a guide to dismantling, for assembly the sequence should be reversed.
<GRAPHIC
<GRAPHIC
C055300-C1
Fig 6.
Renew ‘O’ rings
8
7
7
4
6
5
<GRAPHIC
<GRAPHIC
C055310-C1
Fig 7.
DO NOT attempt to fit position sensor to casing with selector sensor
2
4
Fit to gearbox casing with fork end of shank lever locating over dowel B in selector fork
3
<GRAPHIC
<GRAPHIC
C055730-C1
Fig 8.
Engage flat bladed screwdriver
C
D
7
B
4
7
Gearbox
Gearbox
Removal
Removal
<GRAPHIC
<GRAPHIC
C056810
Fig 9.
2/4 wheel drive and front and rear P.T.O. functions are ECU controlled, consequently if incorrect operation is reported, error c…
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
Make sure that no-one goes near the machine while you install or remove the mechanical device.
2/4 wheel drive and front and rear P.T.O. functions are ECU controlled, consequently if incorrect operation is reported, error c…
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
2/4 wheel drive and front and rear P.T.O. functions are ECU controlled, consequently if incorrect operation is reported, error c…
The numerical sequence is a guide to removal, for replacement the sequence should be reversed.
1 Remove cab. See
1 Remove cab. See
Section B
2 Drain oil from transmission. See
Section 3
3 Remove all protection plates and cross members, except transmission mounting cross member
1
4 Remove rear axle drive propshaft
2
3
5 Remove four wheel drive propshaft to front axle (not illustrated) and front PTO drive shaft from yoke
4
As hydraulic hoses are disconnected from the transmission, they should be plugged and their associated adapters capped to prevent ingress of dirt. The hoses should also be clearly marked for correct replacement.
6 Remove transmission cooler hoses
5
7
8
7 Drain hydraulic tank, remove suction hoses
9
10
11
12
8 With cab removed electrical connections to the transmission will be disconnected at the main multi pin plug, consequently the transmission loom
13
If any part of the transmission wiring harnesses are renewed then a full recalibration must be performed on transmission.
9 Remove transmission filter and housing
14
10 Disconnect, plug and label all pressure test point hoses from the transmission selector valve.
11 Remove transmission dip stick, tube and filler tube.
12 Arrange suitable overhead crane with spreader bar and adjustable length chains
A
15
16
B
17
A
13 Allow overhead crane to take weight.
14 Arrange a jack to support the rear of the engine. Remove crossmember
1
15 With the load adequately supported, remove all wet clutch housing to flywheel housing bolts
18
<GRAPHIC
<GRAPHIC
C056830
Fig 10.
16 Fit rear engine support
19
20
19
C
17 Slowly begin to lift transmission with the overhead crane whilst lowering the rear with block and tackle
B
Replacement
Replacement
Replacement is a reversal of the removal sequence with the following precautions.
Care should be taken when lowering the transmission into the chassis that no damage occurs between the wet clutch housing and the heater pipes
21
6
Dismantling and Assembly
Dismantling and Assembly
The procedures for dismantling and assembling the gearbox are described in the
JCB Transmissions Service Manual
Page left intentionally blank
Front Axle
Front Axle
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Removal and Replacement – Differential Oil Seal ( T F3-2)
K Removal and Replacement – Differential Oil Seal ( T F3-2)
<TABLE ROW
K Removal and Replacement ( T F3-4)
K Removal and Replacement ( T F3-4)
<TABLE ROW
K Dismantling and Assembly – Hub and Drive Shaft ( T F3-7)
K Dismantling and Assembly – Hub and Drive Shaft ( T F3-7)
<TABLE ROW
K Removal and Replacement – Drive Head ( T F3-14)
K Removal and Replacement – Drive Head ( T F3-14)
<TABLE ROW
K Dismantling and Assembly – Drive Head ( T F3-16)
K Dismantling and Assembly – Drive Head ( T F3-16)
<TABLE ROW
K Dismantling and Assembly – Differential ( T F3-23)
K Dismantling and Assembly – Differential ( T F3-23)
Removal and Replacement – Differential Oil Seal
Removal and Replacement – Differential Oil Seal
This job can be done with the axle either removed or in situ on the machine.
1 Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.
A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensu…
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
1 Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.
1 Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.
<GRAPHIC
<GRAPHIC
Fig 1.
2 Drain the oil from the rear axle casing or front axle differential casing as applicable (see
Section 3 – Routine Maintenence
3 Remove the seal and fit a new one. Take care not to damage the housing when removing the old oil seal. Lubricate the lips of t…
4 Install the old stake nut temporarily. Then, using a torque wrench determine the torque required to align the scribed lines (see step 1). Remove and discard the old stake nut.
5 Before fitting the flange, check that its bearing end is not fretted and renew if required. Clean any oil from the splines of …
6 Fit the coupling flange with a new stake nut.
<GRAPHIC
<GRAPHIC
<GRAPHIC
Fig 2.
a Using Service Tool 892/00812, tighten nut to 250Nm (184 lbf ft, 25.5 kgf m).
b Measure the rolling torque. The reading should be 0.5 to 1 Nm (0.37 to 0.74 lbf ft, 0.05 to 0.1 kgf m) more than that recorded in Step 1 (see Note).
c If necessary, progressively torque tighten nut to achieve correct rolling torque.
If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in Step 1 by more than 1 Nm (0.74 lbf ft, 0.1 kgf m), then the spacer mounted on the axle pinion must be renewed.
d Stake the nut using a square ended staking tool.
7 Fill the axle or differential casing with the specified oil, (see
Section 3 – Routine Maintenence
Removal and Replacement
Removal and Replacement
<GRAPHIC
<GRAPHIC
Fig 3.
Removal
Removal
Fig 3. (X F3-4)
Fig 3. (X F3-4)
1 Remove the four nuts
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
1 Remove the four nuts
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
1 Remove the four nuts
1 Remove the four nuts
M
2 Loosen the front road wheel retaining nuts.
3 Position a jack
A
B
4 Position axle stands
B
An alternative is to hoist the whole of the front of the machine (if suitable equipment is available) and then insert axle stands. Position a jack beneath the axle and raise it to take the axle weight.
5 Remove the road wheels and drain oil from hubs and axle.
a ABS Machines only
a ABS Machines only
Disconnect the axle mounted speed sensor flying leads, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.
6 Disconnect brake pipes
C
7 Disconnect the steering drag link from the steering lug on the right side hub.
8 Remove the shock absorbers
E
9 Disconnect the 4WD shaft at
F
10 Remove Panhard rod
G
11 Completely remove anti-roll bar
Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure.
11 Completely remove anti-roll bar
L
12 Lower the jack
A
H
13 Lever the springs so that they are not jammed on axle spigots
J
14 With the axle still supported by the jack, disconnect the three control arms
Keep your hands clear of the springs until they have been released and are no longer under load or you may trap your fingers.
14 With the axle still supported by the jack, disconnect the three control arms
K
Section S –
Front Suspension System
Replacement
Replacement
Fig 3. (X F3-4)
Fig 3. (X F3-4)
Replacement is the reverse of the removal procedure. Ensure that the chassis is correctly supported as in Removal Step 4.
Do the following replacement procedures:
– Shock Absorbers (see
– Shock Absorbers (see
Section S – Front Suspension SYSTEM
– Panhard Rod (see
Section S – Front Suspension SYSTEM
– Control Arms (see
Section S – Front Suspension SYSTEM
– Propshaft (see
Section F – Propshafts
When refitting the fender assemblies tighten nuts
M
On completion, fill the axle with the correct oil (see
Section 3 – Routine Maintenence
Bleed the brakes (see
Section G
Dismantling and Assembly – Hub and Drive Shaft
Dismantling and Assembly – Hub and Drive Shaft
<GRAPHIC
<GRAPHIC
Fig 4.
Dismantling
Dismantling
Fig 4. (X F3-7)
Fig 4. (X F3-7)
1 Ensure that oil has been drained from the hubs and axle. Remove screws
1 Ensure that oil has been drained from the hubs and axle. Remove screws
1
2 Use a ball joint splitter to separate the steering connections from the lugs on the hub. Disconnect the flexible brake pipe.
3 Lever off the planet gear carrier
Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure.
3 Lever off the planet gear carrier
2
3
4
4 Remove the planet gears
4
4
5
6
4
7
4
<GRAPHIC
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Fig 5.
5 To remove driveshaft thrust pad
8,
6 Remove circlip
9
10
7 To remove the spacer
11
12
11
8 Remove the M14 Verbus Ripp bolts
12
9 See Note below. Using three bolts
12
If the hub swivel
14
13
14
13
10 Remove circlip
15
16
13.
11 Remove the brake calipers (see
Section G
Section G
Wheel Hub Service Kit 892/01092 (see
Service Tools
Fig 6. (X F3-9)
<GRAPHIC
<GRAPHIC
Fig 6.
12 Assemble the puller
B
A
Reaction tube
C
13 Screw in
D
17
19
Y
If
D
If necessary, the brake disc
18
17
27
18
Section G – Brakes – Brake SYSTEM.
<GRAPHIC
<GRAPHIC
Fig 7.
14 Remove and discard the combination seal
21
<GRAPHIC
<GRAPHIC
Fig 8.
15 Assemble the puller
B
E
20
F
C
Reaction tube
C
16 Slowly screw in
D
20
17 Remove the outer races of bearings
19
20
17
18 Mark the position of the top trunnion
22
14
23
22
24
23B
14
19 Pull off the trunnion bearings
25
26
20 Withdraw the driveshaft assembly
28
Check the wear sleeve adjacent to the shoulder at the outer end of inner drive shaft
39
<GRAPHIC
<GRAPHIC
<GRAPHIC
Fig 9.
a Place the sleeve
X
b To fit a new sleeve it is necessary to pre-heat it to 100 – 110 ˚C (212 – 230 ˚F). To avoid personal injury from burning, wear gloves and protective overalls. After pre-heating use a suitable tube to press or tap the wear sleeve
X
21 Prise out the driveshaft oil seal
29
22 Remove circlip
30
23 Remove the bearing
31
24 Remove the oil seal
33
14
25 Remove the needle bearing
34
14
Assembly
Assembly
Fig 4. (X F3-7)
Fig 4. (X F3-7)
If the driveshafts have been separated, assemble them in the reverse order of dismantling.
1 Tap in the driveshaft inner bearing
1 Tap in the driveshaft inner bearing
31
30
2 Pack JCB HP Grease between the lips of the new oil seal
29
3 Fit the driveshaft
28
4 Fit a new needle bearing
34
14
33
5 Press a new trunnion inner oil seal
26
25
6 Locate the hub swivel
14
28
22
23B
Table 1. Torque Settings, Zinc- plated (colour: golden) (X F3-13)
7 Refit original shim
24
22
23A
Axles assembled from new without any shims
24
24
<GRAPHIC
<GRAPHIC
Fig 10.
8 Fig 10. (X F3-11) Attach a spring balance to the track rod swive and measure the turning load on the hub swivel. Tighten the top trunnion bolts just enough to eliminate end float without introducing bearing pre- load. i.e. no increase in spring balan
8 Fig 10. (X F3-11)
9 Measure the gap at the top trunnion and subtract 1 mm to give bearing pre-load. Add the result to nominal shim at top trunnion to give a provisional total shim thickness which must be verified as follows.
10 Refit top trunnion
22
Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)
Apply JCB Threadlocker and Sealer to all four studs 23. Fit the studs and torque tighten.
Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)
11 Fit the brake disc
18
17,
27
Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)
12 Before fitting bearings and oil seal
21
13 Install outer bearing race from bearing
19
17
14 Lightly oil the inner wheel bearing cone
20
17
<GRAPHIC
<GRAPHIC
Fig 11.
15 Use service tool 892/00891(see Note below) to drive the seal
21
17
Fig 11. (X F3-11)
Do not lubricate the seal before fitting.
Service tool 892/00891 has been produced in two different versions. The latest version supplied with the Wheel Hub Service Kit 8…
Wheel hub service kit 892/01092 (see
Service Tools
<GRAPHIC
<GRAPHIC
Fig 12.
16 Attach the bearing centre puller
H
When fitting the annulus carrier, new ‘Verbus Ripp’ bolts must be used.
17 Lightly oil the inner wheel bearing
20
H
<GRAPHIC
<GRAPHIC
Fig 13.
18 Slide the bearing fitting tube
K
H
19 Attach the puller handle
J
H
L.
K
20
20 Remove the puller handle
J
K
21 Install the outer bearing
19
17
22 Assemble the puller handle
J
K
H
L
23 Using the puller handle
J
K
19
Do not overtighten or the bearing will be damaged.
24 Remove puller handle
J
K
H
25 Assemble the annulus ring
16
15
26 Fit the annulus assembly to the hub swivel in the same angular position as it was prior to removal.
Dismantling (X F3-8)
12
13
14
12
27 Check the seal drag rolling force as follows:
<GRAPHIC
<GRAPHIC
Fig 14.
Temporarily refit the planet gear carrier
2
Do not fit the sun gear
10
Rotate the hub several turns to bed-in the seal.
Fig 14. (X F3-12) Using a spring balance and cord wrapped around the planet carrier flange as shown. Pull the spring balance so that the hub rotates; record the rolling force reading. (Ignore the extra force needed to start the rotation.)
Fig 14. (X F3-12)
Remove the planet gear carrier after checking rolling force.
28 Torque tighten bolts
12
Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)
29 Check the rolling force of the bearings as follows.
Refit the planet gear carrier
2
Do not fit the sun gear
10
Fig 14. (X F3-12) Using a spring balance and cord wrapped around the planet carrier flange as shown. Pull the spring balance so that the hub rota…
Fig 14. (X F3-12)
Renew bearings if necessary. Remove the planet gear carrier after checking rolling force.
A high rolling force reading may indicate that the combination seal was damaged during fitting.
30 Press the driveshaft thrust pad
8
2
31 Fit new planet gears
4
Dismantling (X F3-8)
7
If planet gears
4
10
32 Slide on the spacer
11
10
37
9
33 Fit a new ‘O’ ring
3
34 Fit the planet carrier
2
17
1
Table 1. Torque Settings, Zinc-plated (colour: golden) (X F3-13)
Never hit the hub in the centre with a hammer. Hammering will dislodge the thrust pad
8
On ABS machines replace the ABS sensors (see
Section G
35 Fit the brake calipers (see
Section G
36 Refill the hub with oil (see
Section 3
37 If any of the steering linkage parts have been renewed or disturbed, check and, if necessary, adjust wheel alignment (see
Section 3
Table 1. Torque Settings, Zinc-plated (colour: golden)
Table 1. Torque Settings, Zinc-plated (colour: golden)
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1
1
56
5.7
42
<TABLE ROW
12
12
320
33
236
<TABLE ROW
23
23
98
10
72
<TABLE ROW
23B
23B
158
16
72
<TABLE ROW
27
27
166
17
123
Removal and Replacement – Drive Head
Removal and Replacement – Drive Head
<GRAPHIC
<GRAPHIC
Fig 15.
This job can be done with the axle either removed or in situ on the machine.
Removal
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
Removal
Removal
If the axle is in situ do steps 1 to 2a; if the axle is removed begin at step 3.
1 Jack up the machine and support it on axle stands.
1 Jack up the machine and support it on axle stands.
2 Remove the road wheels and drain the oil from axle. Disconnect the drag link from the steer hub, using a suitable ball joint splitter.
a ABS machines only
a ABS machines only
Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure.
a ABS machines only
Disconnect the axle mounted speed sensor flying leads, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.
3 Remove split pins
1
2.
3
4 Disconnect hydraulic pipes at brake calipers
B
D
4, 5
Dismantling (X F3-8)
5 Pull the complete hub and swivel assemblies
6
6 Disconnect the propshaft.
7 Support the drive head
8
7
8
9
8 Remove and discard axle oil seals
10
Replacement
Replacement
Replacement is the reverse of the removal procedure.
Use a new gasket
9
Pack JCB HP Grease between the lips of new seals
10
Set front wheel alignment (see
Section 3
2
1
The damper mounting pin on the track rod should be uppermost and closest to the RH end of the axle.
Bleed the braking system.
Dismantling and Assembly – Drive Head
Dismantling and Assembly – Drive Head
<GRAPHIC
<GRAPHIC
Fig 16.
Dismantling
Dismantling
1 Remove the drive head from the axle.
Fig 16. (X F3-16)
1 Remove the drive head from the axle.
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
1 Remove the drive head from the axle.
1 Remove the drive head from the axle.
Removal and Replacement – Drive Head (X F3-14)
2 Remove circlip
3
3 Apply compressed air to the oil feed port (hydraulic connector
38
4
5
6
4 Remove piston
7
8
5 Remove compression spring
9
10
11
12
6 Remove the roll pins
13
14
15
16
Section 1
7 Lay the drive head on a flat surface positioned with the split bearing carrier uppermost. The weight of the assembly
20
17
8 Rotate the drive head through 90˚ to lie in the position shown in the illustration. Undo bolts
18
2A
19
17
9 Rotate drive head back through 90˚ to the vertical position and remove the differential assembly
20
10 Remove bolts
21
24
25
23
11 Remove the pinion nut
26
27
12 Remove the drive flange
27
13 Drive the pinion shaft
28
14 Prise the shaft seal
29
15 Remove the taper roller bearing
30
31
16 Tap out the bearing cup
32
17 Remove the spacer
34
35
18 Remove the hydraulic connector
36
37
During a differential lock repair or piston replacement, inspect the housing for scores, marks or damage which could cause a lea…
Assembly
Assembly
Lightly oil all bearings and seals before assembly.
1 Select shims
1 Select shims
33
32
2
Pinion Depth (X F3-19)
2 Fit pinion bearing
35
28
3 Fit spacer
34
Solid Spacer Installation (X F3-20)
4 Fit crown wheel
22
21
5 Fit bearings
24
25
6 Locate differential case assembly
20
7 Position split bearing carrier
2A
18
19
18
8 Rotate drive head through 90˚ so that the differential lock housing is uppermost. Tap bearing cup
17
24
9 Fit both castellated nuts
15
16
Section 1
Solid Spacer Installation (X F3-20)
10 Using a clock gauge with a magnetic base, check the crown wheel backlash. This should be 0.17 mm to 0.28 mm (0.006 to 0.011 i…
11 Apply engineers’ marker to 3 or 4 teeth then check the crown wheel and pinion for correct meshing.
Crown Wheel and Pinion Adjustment (X F3-22)
33
12 Fit roll pin
14
13 Fit a new ‘O’ ring
37
36
14 Secure the drive head with the differential lock housing uppermost.
15 Fit new ‘O’ ring
8
7
7
12
11
10
9
16 Grease the differential lock housing bore and fit sub- assembly over differential lock actuator. Make sure that the piston is inserted squarely into the bore.
17 Fit new ‘O’ rings
5
6
4
4
7
18 Gently tap the differential lock assembly with a soft faced hammer to seat all components.
19 Ensure that the groove
7
15
13
A
20 Compress the assembly sufficiently to fit circlip
3
<GRAPHIC
<GRAPHIC
Fig 17.
Pinion Depth
Pinion Depth
Large Pinion Bearing
Large Pinion Bearing
The crown wheel and pinion are a matched pair and must be renewed as a pair if either component is damaged or excessively worn. Do not use unmatched components.
<GRAPHIC
<GRAPHIC
Fig 18.
Measure direct the depth
W
32
35
W
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 bearing depth; if negative, subtract from bearing depth.
Obtain the deviation figure (e.g. -1) stamped on the bolt flange of housing
B
Subtract the total of the above figures from the standard value of 37.27 mm. the result will be the thickness of shims
33
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Example (all dimensions in millimetres)
Example (all dimensions in millimetres)
<TABLE ROW
Bearing depth W
W
36.61
<TABLE ROW
Pinion deviation (+2)
+0.02
<TABLE ROW
Housing deviation (-1)
+0.01
<TABLE ROW
Total
36.64
<TABLE ROW
<TABLE ROW
Standard value
37.27
<TABLE ROW
Less total above
36.64
<TABLE ROW
Shim thickness
0.63
Use shim pack size to the nearest 0.05 mm.
Solid Spacer Installation
Solid Spacer Installation
Solid spacer setting tools are required for this job (see
Service Tools
1 Install pinion and bearings into the drive head casing. Install largest e.g. 13.6 mm solid spacer
1 Install pinion and bearings into the drive head casing. Install largest e.g. 13.6 mm solid spacer
34
Fig 18. (X F3-19)
<GRAPHIC
<GRAPHIC
Fig 19.
2 Fit special tool sleeve
A
B
A
3 Fit special bracket
C
Y
B
Y
B
C
4 Fit dial test indicator (DTI)
Z
C
5 Set torque wrench
E
<GRAPHIC
<GRAPHIC
Fig 20.
6 To select the right size spacer
34
Fig 18. (X F3-19)
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<TABLE
<TABLE HEADING
<TABLE ROW
Example
<TABLE BODY
<TABLE ROW
Temporary spacer size
13.60
<TABLE ROW
Subtract end-float
0.52
<TABLE ROW
Total
13.08
<TABLE ROW
Subtract tolerance & preload
0.06
<TABLE ROW
Result
13.02
<TABLE ROW
(No spacer available this size, use next closest size spacer i.e 13.00.)
7 Remove sleeve
A
8 Fit sleeve
A
B
9 If rolling torque measured at 8 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.
10 Remove adapter
B
A
11 Progressively torque tighten retaining nut to 300 Nm. Provided the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.
The nut tightening torque can be increased to a maximum of 390 Nm provided that the rolling torque does not exceed the maximum of 3.4 Nm.
12 Finally stake the nut into the slot.
Crown Wheel and Pinion Adjustment
Crown Wheel and Pinion Adjustment
Meshing of the gears should be checked by marking three of the pinion teeth with engineers’ marking compound and rotating the pinion.The marking will then be transferred to the crown wheel teeth.
<GRAPHIC
<GRAPHIC
Fig 21. Correct tooth marking.
<GRAPHIC
<GRAPHIC
Fig 22. Pinion too deeply in mesh
Fig 18. (X F3-19) Decrease the thickness of shim
Fig 18. (X F3-19)
33
<GRAPHIC
<GRAPHIC
Fig 23. Pinion too far out of mesh
Fig 18. (X F3-19) Increase the thickness of shim
Fig 18. (X F3-19)
33
Dismantling and Assembly – Differential
Dismantling and Assembly – Differential
<GRAPHIC
<GRAPHIC
Fig 24.
Dismantling
Dismantling
The numerical sequence is intended as a guide to dismantling.
For assembly the sequence should be reversed.
1 Secure the assembly in a vice or suitable jig for dismantling and examination.
1 Secure the assembly in a vice or suitable jig for dismantling and examination.
2 Remove the bolts
1
2
3 Remove actuating sleeve
3
4 Remove 11 counter plates
4
5
8
5 Separate the differential case halves
6
14
6 Remove the pinion gear
8
10
9
11
7
13
Assembly
Assembly
The bevel gears are a matched set, as are the two differential case halves also the crown wheel and pinion. These must be renewed as sets if any of their components are damaged or excessively worn. Do not use unmatched components.
The differential case halves are stamped for matching purposes. The stamp on the crown wheel case half can only be seen when the crown wheel is removed.
1 Assemble the trunnion pins
1 Assemble the trunnion pins
9
8, 10, 12
7, 11
13
14
2 Position the differential case half
6
3 Fit 11 counter plates
4
5
4 Position the actuating sleeve
3
2
6
5 Check free rotation of the gears in the horizontal position (If held vertically the friction and counter plates would prevent rotation).
6 Using a hand pump test the differential lock for correct operation and leaks. Do not exceed a pressure of 35 bar (500 lbf/in
2
7 When satisfactory, apply JCB Threadlocker and Sealer to the threads of bolts
1
Rear Axle
Rear Axle
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Removal and Replacement – Differential Oil Seal ( T F4-2)
K Removal and Replacement – Differential Oil Seal ( T F4-2)
<TABLE ROW
K Dismantling and Assembly – Rear PTO Drive Shaft ( T F4-4)
K Dismantling and Assembly – Rear PTO Drive Shaft ( T F4-4)
<TABLE ROW
K Installation – Rear PTO Output Shaft ( T F4-6)
K Installation – Rear PTO Output Shaft ( T F4-6)
<TABLE ROW
K Removal and Replacement ( T F4-7)
K Removal and Replacement ( T F4-7)
<TABLE ROW
K Dismantling and Assembly – Hub and Drive Shaft ( T F4-10)
K Dismantling and Assembly – Hub and Drive Shaft ( T F4-10)
<TABLE ROW
K Removal and Replacement – Drive Head ( T F4-13)
K Removal and Replacement – Drive Head ( T F4-13)
<TABLE ROW
K Dismantling and Assembly – Drive Head ( T F4-15)
K Dismantling and Assembly – Drive Head ( T F4-15)
<TABLE ROW
K Dismantling and Assembly – Differential ( T F4-23)
K Dismantling and Assembly – Differential ( T F4-23)
Removal and Replacement – Differential Oil Seal
Removal and Replacement – Differential Oil Seal
This job can be done with the axle either removed or in situ on the machine.
1 Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.
A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensu…
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
1 Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.
1 Remove the road wheels and uncouple the axle driveshaft. Measure the axle rolling torque and record the reading. Mark the relative positions of the pinion shaft and nut with a scriber.
<GRAPHIC
<GRAPHIC
Fig 1.
2 Drain the oil from the rear axle casing or front axle differential casing as applicable (see
Section 3 – Routine Maintenence
3 Remove the seal and fit a new one. Take care not to damage the housing when removing the old oil seal. Lubricate the lips of t…
4 Install the old stake nut temporarily. Then, using a torque wrench determine the torque required to align the scribed lines (see step 1). Remove and discard the old stake nut.
5 Before fitting the flange, check that its bearing end is not fretted and renew if required. Clean any oil from the splines of …
6 Fit the coupling flange with a new stake nut.
<GRAPHIC
<GRAPHIC
<GRAPHIC
Fig 2.
a Using Service Tool 892/00812, tighten nut to 250Nm (184 lbf ft, 25.5 kgf m).
b Measure the rolling torque. The reading should be 0.5 to 1 Nm (0.37 to 0.74 lbf ft, 0.05 to 0.1 kgf m) more than that recorded in Step 1 (see Note).
c If necessary, progressively torque tighten nut to achieve correct rolling torque.
If the rolling torque figure (new pinion seal fitted) exceeds the reading recorded in Step 1 by more than 1 Nm (0.74 lbf ft, 0.1 kgf m), then the spacer mounted on the axle pinion must be renewed.
d Stake the nut using a square ended staking tool.
7 Fill the axle or differential casing with the specified oil, (see
Section 3 – Routine Maintenence
Dismantling and Assembly – Rear PTO Drive Shaft
Dismantling and Assembly – Rear PTO Drive Shaft
<GRAPHIC
<GRAPHIC
Fig 3.
The numerical sequence is intended as a guide to dismantling.
K Fig 3. ( T F4-4)
The numerical sequence is intended as a guide to dismantling.
For assembly the sequence should be reversed.
When Dismantling
When Dismantling
Undo bolts
4
5
Disconnect prop shaft from drive flange
8
7
8
Drive out shaft
10
13
Catch inner bearing race
11
14
Assembly
Assembly
Soak oil seal
6
1 Use a suitable length of tube to drive new inner bearing race
1 Use a suitable length of tube to drive new inner bearing race
14
10
Pre pack bearings with JCB HP Grease.
2 Fit bearing cup
12
15
13
10
11
9
3 Apply an even 2 mm bead of JCB Threadlocker and Sealer around the outer end of the drive shaft spline at the drive flange end. Fit drive flange
8
7
4 Tighten stake nut
7
5 Continue tightening stake nut
7
13
If the specified rolling torque is exceeded, the collapsible spacer
13
6 When pre-load has been set, stake nut
7
7 Pack JCB HP grease between the lips of a new rear oil seal
6
8 Check that the final rolling torque with the rear oil seal fitted is approximately 5 Nm (3.7 lbf ft) greater than that measured in step 5.
9 Before fitting the PTO output shaft
3
2
1
K Installation – Rear PTO Output Shaft ( T F4-6)
10 The rear PTO propshaft must be fitted with the sliding joint at the axle end to prevent the possibility of fouling when the limit of suspension travel is reached.
When assembly is complete, grease both drive shaft bearings
11
14
Section 3 – Greasing
Installation – Rear PTO Output Shaft
Installation – Rear PTO Output Shaft
General
General
All models have a two speed capability for PTO drive. Two rear PTO output shafts are available, as detailed below, to suit differing implement shaft sizes, speeds and power requirements.
The standard 35 mm (13/8 in) output shaft
A
The optional 45 mm (13/4 in) shaft
B
As a general rule, only use the 6 spline (540 PTO RPM) end of shaft
A
A
B
Fitting
Fitting
Fig 3. (X F4-4)
Fig 3. (X F4-4)
K Fig 4. ( T F4-6)
K Fig 4. ( T F4-6)
Tilt the PTO guard
5
To reverse standard shaft
A
1
2
When optional shaft
B
1
2
<GRAPHIC
<GRAPHIC
Fig 4.
Removal and Replacement
Removal and Replacement
<GRAPHIC
<GRAPHIC
Fig 5.
Removal
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
Removal
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Removal
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
Removal
Removal
Fig 5. (X F4-7)
Fig 5. (X F4-7)
1 Position trolley jacks under the axle and raise the wheels off the ground.
1 Position trolley jacks under the axle and raise the wheels off the ground.
2 Remove the road wheels and drain oil from the hubs/ axle.
a ABS Machines only
a ABS Machines only
Disconnect the axle mounted speed sensor flying leads, one at each hub, from their chassis mounted mating connectors. Tie the cable sheathing to the axle for protection during the following procedure.
3 Disconnect brake pipes
A
B
C
4 Disconnect and remove the draft pins and the position sensor, (see
Section B
E
D1
D
B
5 Slacken the linkage bracket bolts
G
H
6 Remove the circlips
J
B
B
7 Remove driveshafts (i.e. main drive and PTO).
8 Lower the rear suspension so that the chassis sits on its bump stops
9 Wait for the suspension to rise and repeat step 8 to fully discharge the oil pressure in the hydraulic circuit. Disconnect both position sensor link rods
L
T
10 Disconnect the lower pin of the two suspension cylinders
N
11 Jack up the axle and chassis, place axle stands under the tube cross member. Fully support or sling the axle.
12 Remove the clamps/bushes
P
R
Section S – Rear Suspension SYSTEM
13 Disconnect the ‘V’ link arm
S
14 Disconnect the two control arms
T
15 If rebound straps are fitted as shown at
V
W
16 If using an overhead gantry, lower the axle slightly and move it out to the rear. If using a jack then lower the axle and drag to the rear.
Replacement
Replacement
Fig 5. (X F4-7)
Fig 5. (X F4-7)
Replacement is a reversal of the removal procedure.
Before fitting bolts
G
Treat all bolt threads with JCB Threadlocker and Sealer. Tighten bolts
G
Ensure that bushes
X
W
Do the following replacement procedures:
– Suspension Cylinders (see
– Suspension Cylinders (see
Section S – Rear Suspension SYSTEM
– Anti-Roll Bar (see
Section S – Rear Suspension SYSTEM
– ‘V’ Link (see
Section S – Rear Suspension SYSTEM
– Control Arms (see
Section S – Rear Suspension SYSTEM
– Propshaft (see
Section F – Propshafts
Ensure the axle is filled with the correct oil (see
Section 3
Set the rear ride height (see
Section S – Rear Suspension SYSTEM
Bleed the brakes (see
Section G
Dismantling and Assembly – Hub and Drive Shaft
Dismantling and Assembly – Hub and Drive Shaft
<GRAPHIC
<GRAPHIC
Fig 6.
Dismantling
Dismantling
Fig 6. (X F4-10)
Fig 6. (X F4-10)
1 Drain the oil from the axle and hub. Remove screws
1 Drain the oil from the axle and hub. Remove screws
1
2
3
2 Pull out the driveshaft thrust pad
4
3 Remove screws
5
4 Suitably support planet gear carrier
6
7
5 Remove circlip
8
9
10
6 Remove and discard ‘O’ ring
11
7 Remove circlip
12
13
8 Suitably support bearing housing
7
14
15
16
9 Remove bearing housing
7
17
10 Remove the brake caliper (see
Section G
11 If required, unscrew bolts
30
W
18
Section G
12 Remove bearing cups
19
20
13 Remove inner bearing cone
21
23
14 Check bearing spacer
22
15 Check seal shield
X
16 Mark planet gear pins
24
6
17 Support planet gear carrier (pin head downwards) on suitable blocks. Drive out pins
24
Retain pin
24
25
26
27
18 Remove planet gears
28
29
All three pins must be removed before the planet gears can be removed.
Assembly
Assembly
Fig 6. (X F4-10)
Fig 6. (X F4-10)
Stub
Z
Y
Y
1 Secure stub
1 Secure stub
Z
Y
Y
19
20
21
7
2 Before fitting combination seal
23
3 Without dismantling or lubricating the new seal, drive it into the bearing carrier until the locating lip is flush as shown at
B
Fig 7. (X F4-12)
4 Suitably support bearing housing
7
Z
5 Lightly oil the outer wheel bearing cone 18. Fit onto annulus carrier
17
6 Fit the annulus ring
13
17
12
7 Fit annulus assembly (items
18, 17, 13 and 12
Z
16
<GRAPHIC
<GRAPHIC
Fig 7.
Rotate bearing carrier backwards and forwards while carrying out torque tightening sequence.
8 Gradually tighten nut to the lower limit of tightening torque 700 to 1000 Nm (516 to 738 lbf ft). Fit locking plates
15
Do not exceed the upper torque limit.
9 Fit lock plates
15
14
10 Fit new O ring
11
11 Position the three planet gears
28
29
6
12 Position thrust washer
25
24
26
27
13 Align planet gear
28
29
14 Repeat steps 11 and 12 for other two pins.
Make sure that the machined profile on the pin heads is aligned with the side gear carrier machining.
15 Secure brake disc
W
30
7
5.
a ABS machines only
a ABS machines only
Replace the ABS sensor (see
Section G
16 Insert drive shaft, Fit thrust washer
10
9
8
17 Force fit driveshaft thrust pad
4
2
3
18 Fit cover plate into side gear carrier.
19 Apply JCB Lock and Seal to screws
1
Removal and Replacement – Drive Head
Removal and Replacement – Drive Head
<GRAPHIC
<GRAPHIC
Fig 8.
This job can be done with the axle in situ if required.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
This job can be done with the axle in situ if required.
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
Make sure that no-one goes near the machine while you install or remove the mechanical device.
This job can be done with the axle in situ if required.
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
This job can be done with the axle in situ if required.
Removal
Removal
Fig 8. (X F4-13)
Fig 8. (X F4-13)
1 If the axle is in situ, support the chassis.
1 If the axle is in situ, support the chassis.
Removal and Replacement (X F4-7)
2 Remove the road wheels and drain oil from hubs/ axle.
3 Disconnect hydraulic connection
1
4 Disconnect the main propshaft at flange
2
Before removing the drive head, disconnect the rear PTO prop shaft and then remove the PTO driveshaft,
Dismantling and Assembly – Rear PTO Drive Shaft (X F4-4)
5 Remove the two bolts
3
Dismantling (X F4-11)
6 Pull the driveshafts out of the axle.
7 Support the drive head
6
8 Remove bolts
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
8 Remove bolts
5
9 Remove two dowels
7
8
Replacement
Replacement
K Fig 8. ( T F4-13)
K Fig 8. ( T F4-13)
Replacement is the reversal of the removal procedure.
Treat all mating surfaces with JCB Multigasket.
Fit the two bolts 3 (PD70/SD70) and tighten to a torque of 56 Nm (41 lbf ft, 5.7 kgf m).
Treat bolts 5 with JCB Threadlocker and Sealer. Tighten to a torque of 166 Nm (122 lbf ft, 17 kgf m).
Before connecting the propshafts, see
Section F – Propshafts.
Dismantling and Assembly – Drive Head
Dismantling and Assembly – Drive Head
<GRAPHIC
<GRAPHIC
Fig 9.
Dismantling
Dismantling
1 Remove the drive head from the axle.
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
1 Remove the drive head from the axle.
1 Remove the drive head from the axle.
Removal and Replacement – Drive Head (X F4-13)
2 Remove circlip
3
3 Apply compressed air to the oil feed port (hydraulic connector
38
4
5
6
4 Remove piston
7
8
5 Remove compression spring
9
10
11
12
6 Remove the roll pins
13
14
15
16
Section 1
7 Lay the drive head on a flat surface positioned with the split bearing carrier uppermost. The weight of the assembly
20
17
8 Rotate the drivehead through 90˚ to lie in the position shown in the illustration. Undo bolts
18
2A
19
17
9 Rotate drivehead back through 90˚ to the vertical position and remove the differential assembly
20
10 Remove bolts
21
22
24
25
23
11 Remove the pinion nut
26
27
12 Remove the drive flange
27
13 Drive the pinion shaft
28
14 Prise the shaft seal
29
15 Remove the taper roller bearing
30
31
16 Tap out the bearing cup
32
33
17 Remove the spacer
34
35
18 Remove the bleed valve and dust cap
36
37
19 Remove the hydraulic connector
38
39
During a differential lock repair or piston replacement, inspect the housing for scores, marks or damage which could cause a lea…
Assembly
Assembly
Lightly oil all bearings and seals before assembly.
1 Select shims
1 Select shims
33
32
2
Pinion Depth (X F4-19)
2 Fit pinion bearing
35
28
2
3 Fit spacer
34
Solid Spacer Installation (X F4-20)
4 Fit crown wheel
22
21
5 Fit bearings
24
25
6 Locate differential case assembly
20
2.
7 Position split bearing carrier
2A
18
19
18
8 Rotate drive head through 90˚ so that the differential lock housing is uppermost. Tap bearing cup
17
24
9 Fit both castellated nuts
15
16
Section 1
Solid Spacer Installation (X F4-20)
10 Using a clock gauge with a magnetic base, check the crown wheel backlash. This should be 0.17 mm to 0.28 mm (0.006 to 0.011 i…
11 Apply engineers’ marker to 3 or 4 teeth then check the crown wheel and pinion for correct meshing.
Crown Wheel and Pinion Adjustment (X F4-22)
12 Fit roll pin
14
13 Fit bleed valve and cap
36
37
40
14 Secure the drive head with the differential lock housing uppermost.
15 Fit new ‘O’ ring
8
7
7
12
11
10
9
16 Grease the differential lock housing bore and fit sub- assembly over differential lock actuator. Make sure that the piston is inserted squarely into the bore.
17 Fit new ‘O’ rings
5
6
4
4
7
18 Gently tap the differential lock assembly with a soft faced hammer to seat all components.
19 Ensure that the groove
A
7
15
13
A
20 Compress the assembly sufficiently to fit circlip
3
<GRAPHIC
<GRAPHIC
Fig 10.
Pinion Depth
Pinion Depth
Large Pinion Bearing
Large Pinion Bearing
The crown wheel and pinion are a matched pair and must be renewed as a pair if either component is damaged or excessively worn. Do not use unmatched components.
<GRAPHIC
<GRAPHIC
Fig 11.
Measure direct the depth
W
32
35
W
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 bearing depth; if negative, subtract from bearing depth.
Obtain the deviation figure (e.g. -1) stamped on the bolt flange of housing
B
Subtract the total of the above figures from the standard value of 37.27 mm. the result will be the thickness of shims
33
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Example (all dimensions in millimetres)
Example (all dimensions in millimetres)
<TABLE ROW
Bearing depth W
W
36.61
<TABLE ROW
Pinion deviation (+2)
+0.02
<TABLE ROW
Housing deviation (-1)
+0.01
<TABLE ROW
Total
36.64
<TABLE ROW
<TABLE ROW
Standard value
37.27
<TABLE ROW
Less total above
36.64
<TABLE ROW
Shim thickness
0.63
Use shim pack size to the nearest 0.05 mm.
Solid Spacer Installation
Solid Spacer Installation
Solid spacer setting tools are required for this job (see
Service Tools
1 Fig 11. (X F4-19) Install pinion and bearings into the drive head casing. Install largest e.g. 13.6 mm solid spacer
1 Fig 11. (X F4-19) Install pinion and bearings into the drive head casing. Install largest e.g. 13.6 mm solid spacer
1 Fig 11. (X F4-19)
34
<GRAPHIC
<GRAPHIC
Fig 12.
2 Fit special tool sleeve
A
B
A
3 Fit special bracket
C
Y
B
Y
B
C
4 Fit dial test indicator (DTI)
Z
C
5 Set torque wrench
E
<GRAPHIC
<GRAPHIC
Fig 13.
6
Fig 11. (X F4-19)
34.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Example
<TABLE BODY
<TABLE ROW
Temporary spacer size
13.60
<TABLE ROW
Subtract end-float
0.52
<TABLE ROW
Total
13.08
<TABLE ROW
Subtract tolerance & preload
0.06
<TABLE ROW
Result
13.02
<TABLE ROW
(No spacer available this size, use next closest size spacer i.e 13.00.)
7 Remove sleeve
A
8 Fit sleeve
A
B
9 If rolling torque measured at 8 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.
10 Remove adapter
B
A
11 Progressively torque tighten retaining nut to 300 Nm. Provided the correct size spacer has been selected the rolling torque should be between 2.3 and 3.4 Nm including seal drag.
The nut tightening torque can be increased to a maximum of 390 Nm provided that the rolling torque does not exceed the maximum of 3.4 Nm.
12 Finally stake the nut into the slot.
Crown Wheel and Pinion Adjustment
Crown Wheel and Pinion Adjustment
Meshing of the gears should be checked by marking three of the pinion teeth with engineers’ marking compound and rotating the pinion.The marking will then be transferred to the crown wheel teeth.
<GRAPHIC
<GRAPHIC
Fig 14. Correct tooth marking.
<GRAPHIC
<GRAPHIC
Fig 15. Pinion too deeply in mesh
Fig 11. (X F4-19) Decrease the thickness of shim
Fig 11. (X F4-19)
33
<GRAPHIC
<GRAPHIC
Fig 16. Pinion too far out of mesh
Fig 11. (X F4-19) Increase the thickness of shim
Fig 11. (X F4-19)
33
Dismantling and Assembly – Differential
Dismantling and Assembly – Differential
<GRAPHIC
<GRAPHIC
Fig 17.
The numerical sequence is intended as a guide to dismantling.
For assembly the sequence should be reversed.
Dismantling
Dismantling
1 Secure the assembly in a vice or suitable jig for dismantling and examination.
1 Secure the assembly in a vice or suitable jig for dismantling and examination.
2 Remove the bolts
1
2
3 Remove actuating sleeve
3
4 Remove 11 counter plates
4
5
8
5 Separate the differential case halves
6
14
6 Remove the pinion gear
8
10
9
11
7
13
Assembly
Assembly
The bevel gears are a matched set, as are the two differential case halves also the crown wheel and pinion. These must be renewed as sets if any of their components are damaged or excessively worn. Do not use unmatched components.
The differential case halves are stamped for matching purposes. The stamp on the crown wheel case half can only be seen when the crown wheel is removed.
1 Assemble the trunnion pins
1 Assemble the trunnion pins
9
8, 10, 12
7, 11
13
14
2 Position the differential case half
6
3 Fit 11 counter plates
4
5
4 Position the actuating sleeve
3
2
6
5 Check free rotation of the gears in the horizontal position (If held vertically the friction and counter plates would prevent rotation).
6 Using a hand pump test the differential lock for correct operation and leaks. Do not exceed a pressure of 35 bar (500 lbf/in
2
7 When satisfactory, apply JCB Threadlocker and Sealer to the threads of bolts
1
Propshafts
Propshafts
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Removal and Replacement ( T F5-2)
K Removal and Replacement ( T F5-2)
Removal and Replacement
Removal and Replacement
There are three types of propshaft coupling, two of which, flange coupled types
A
B
C
D
E
<GRAPHIC
<GRAPHIC
A290601-B1
Fig 1.
Removal
Removal
Disconnecting propshafts will cause the park brake to be ineffective. Block all four wheels before separating a propshaft joint.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
Disconnecting propshafts will cause the park brake to be ineffective. Block all four wheels before separating a propshaft joint.
Before separating any of the drive shaft couplings (flange plates, universal joints, splined shafts), mark both halves to ensure correct positioning on reassembly.
Coupling Type A
Coupling Type A
<GRAPHIC
<GRAPHIC
A302390-B1
Fig 2.
1 Remove nuts
1 Remove nuts
1
2
2 Retract flange
3
Coupling Type B
Coupling Type B
<GRAPHIC
<GRAPHIC
A343820-B1
Fig 3.
1 Remove nuts 5/bolts
1 Remove nuts 5/bolts
6
Coupling Type C
Coupling Type C
<GRAPHIC
<GRAPHIC
A343810-B1
Fig 4.
1 Remove and discard Verbus Ripp bolts
1 Remove and discard Verbus Ripp bolts
9
10
11
2 Remove the rear driveshaft by lowering to the ground. Remove the front driveshaft by withdrawing it from the driveshaft protective bracket.
Coupling Type D
Coupling Type D
<GRAPHIC
<GRAPHIC
S302531-B1
Fig 5.
1 Remove bolts
1 Remove bolts
12
13
14
2 Lower the end of the shaft clear of yoke
15
Coupling Type E
Coupling Type E
Not illustrated
1 This has a yoke end with sliding splines. After disconnecting the other end of the shaft, slide the splined yoke off the mating shaft.
1 This has a yoke end with sliding splines. After disconnecting the other end of the shaft, slide the splined yoke off the mating shaft.
Replacement
Replacement
Lay each propshaft on a flat surface to check that both ends are exactly on the same plane, as shown at
X
Y
Z
Replacement is basically the reverse of the removal procedure but ensure match-marks are aligned (see Step 1 in Removal).
Verbus Ripp bolts
9
<GRAPHIC
<GRAPHIC
Fig 6.
– On Type
– On Type
D
12
13
– On Type
E
– The rear PTO propshaft must be fitted with the sliding joint at the axle end to prevent the possibility of fouling when the limit of suspension travel is reached.
– Torque tighten the nuts.
K Torque Settings ( T F5-4)
– Thoroughly purge all universal joints with grease. If any bearing fails to purge, move the shaft from side to side and then purge. This allows greater clearance on the thrust end of the bearing that is not purging. Wipe away any excess grease.
Table 1. Torque Settings
Table 1. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1
1
120
12.24
88.5
<TABLE ROW
5
5
80
8.16
59
<TABLE ROW
9
9
62.5
6.38
46.1
<TABLE ROW
12
75 – 85
7.65 – 8.7
55.3 – 62.7
<GRAPHIC
<GRAPHIC
A306260-B1
Fig 7.

SectionG
Brake SYSTEM (Non-ABS)
Brake SYSTEM (ABS)
Service Brake Calipers
Park Brake Caliper
Service Brakes Air Valve
Air/Hydraulic Actuator
Air Dryer/Unloader Valve
Non Return Air Valve
Failure Conscious Reducing Valve (Non ABS)
Circuit Protection Valve
ABS Sensors (ABS)
Pressure Modulating Valves (ABS)
Trailer Brake Air Valve
Trailer Brake Hydraulic Valve
Trailer Brake Inverse Relay Valve
Trailer Brake Control Line Air Filter
Trailer Brake Couplings (Palm Couplings)

SectionH
Section H
Section H
Steering
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – 3000 XTRA Series Fastrac
Service Manual – 3000 XTRA Series Fastrac
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Hitches and Attachments
Section A – Hitches and Attachments
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Steering
Section H – Steering
<TABLE ROW
Section S – Suspension
Section S – Suspension
<TABLE ROW
Section T – Engine
Section T – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Steering SYSTEM
Steering SYSTEM
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system..
<TABLE ROW
Descriptions and procedures relate to the system and not the individual devices.
<TABLE ROW
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Technical Data ( T H1-2)
K Technical Data ( T H1-2)
<TABLE ROW
K Operation Overview ( T H1-3)
K Operation Overview ( T H1-3)
<TABLE ROW
K Fault Finding ( T H1-5)
K Fault Finding ( T H1-5)
<TABLE ROW
K Pressure Testing – Steering Pump ( T H1-8)
K Pressure Testing – Steering Pump ( T H1-8)
<TABLE ROW
K Limit Valve Setting ( T H1-10)
K Limit Valve Setting ( T H1-10)
<TABLE ROW
K Wheel Alignment ( T H1-12)
K Wheel Alignment ( T H1-12)
Technical Data
Technical Data
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Pump
<TABLE ROW
Type
Rear section (P2) of gear type pump, driven by gearbox
<TABLE ROW
Controlled flow at 1500 rev/min and system pressure
18 litres/min (4 UK gal/min, 4.8 US gal/min) +15% -10%
<TABLE ROW
Relief valve pressure at 1500 rev/min engine speed
135 bar (1958 lb/in2)
2
DO NOT set the pressure above this value.
Operation Overview
Operation Overview
<GRAPHIC
<GRAPHIC
C097020
Fig 1.
The front axle is steered by a recirculating ball hydraulically power assisted steering box
1
2
3
5
6
Steering damper
7
3
The steering input shafts are supported by bearings and chassis mounted brackets
8
9
10
12
Hydraulic Operation and Schematics
Hydraulic Operation and Schematics
<GRAPHIC
<GRAPHIC
C097030
Fig 2.
P3 is the rear section of the gearbox-driven hydraulic pump which draws fluid from tank
P3
T
SB
B
CS
Fault Finding
Fault Finding
Introduction
Introduction
Before assuming that the steering box or the pump is the cause of a steering problem, ensure that all other steering system faults have been rectified.
Before using the fault finding tables carry out the following checks:
1 Question the operator and drive the machine to establish the exact nature of the fault.
1 Question the operator and drive the machine to establish the exact nature of the fault.
2 Check that the hydraulic oil is clean and to the correct and that there are no signs of oil leakage from the circuit.
Fault Finding Tables
Fault Finding Tables
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Fault – Heavy Steering ( T H1-6)
K Fault – Heavy Steering ( T H1-6)
<TABLE ROW
Table 1. Fault – Heavy Steering
Table 1. Fault – Heavy Steering
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Is the front axle overloaded?
YES:
Reduce load
<TABLE ROW
NO:
Check 2
<TABLE ROW
2
Are the correct tyres fitted and correctly inflated?
YES:
Check 3
<TABLE ROW
NO:
Replace / inflate tyres
<TABLE ROW
3
Is the 4WD clutch releasing correctly?
YES:
Check 4
<TABLE ROW
NO:
See Section F, Fault Finding
<TABLE ROW
4
Is the front differential operating correctly?
YES:
Check 5
<TABLE ROW
NO:
See Section F, Fault Finding
<TABLE ROW
5
Are the steering swivels and linkages free?
YES:
Check 6
<TABLE ROW
NO:
Lubricate and free off
<TABLE ROW
6
Is the oil cooler free of air blockage?
YES:
Check 7
<TABLE ROW
NO:
Clean out debris
<TABLE ROW
7
Is the pump relief valve pressure too low?
YES:
Check for dirt at relief valve
<TABLE ROW
NO:
Check 8
<TABLE ROW
8
Is the pump flow rate too low?
YES:
Check for flow control valve sticking and check 11
<TABLE ROW
NO:
Check 9
<TABLE ROW
9
Is the steering column turning freely?
YES:
Check 10
<TABLE ROW
NO:
Free off / check universal joint phasing
<TABLE ROW
10
Is front wheel alignment correct?
YES:
Check 11
<TABLE ROW
NO:
Adjust
<TABLE ROW
11
Are suspension and steering geometry correct?
YES:
Check 12
<TABLE ROW
NO:
Renew parts as required
<TABLE ROW
12
Is steering box leaking oil?
YES:
Renew seals
<TABLE ROW
NO:
Check 13
<TABLE ROW
13
Is oil temperature high?
YES:
Check cooler and pipework for free flow
<TABLE ROW
NO:
Suspect fault in steering box
Table 2. Fault – Steering Wander or Free Play
Table 2. Fault – Steering Wander or Free Play
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
If the fault is wander, start at check 1. If the fault is free play, start at check 4.
<TABLE ROW
1
Is the rear axle overloaded?
YES:
Reduce load.
<TABLE ROW
NO:
Check 2.
<TABLE ROW
2
Are the correct tyres fitted and correctly inflated?
YES:
Check 3.
<TABLE ROW
NO:
Replace / inflate tyres.
<TABLE ROW
3
Is the front wheel alignment correct?
YES:
Check 4.
<TABLE ROW
NO:
Adjust.
<TABLE ROW
4
Are the column or steering linkages worn or loose?
YES:
Tighten or renew.
<TABLE ROW
NO:
Check 5.
<TABLE ROW
5
Is the pump flow correct?
YES:
Check 6.
<TABLE ROW
NO:
Check condition of flow control.
<TABLE ROW
6
Is air trapped in the hydraulic oil?
YES:
Bleed out air. Turn the steering wheel from lock to lock 3 times and then back to straight ahead (with engine running at idle).
<TABLE ROW
NO:
Suspect fault in steering box.
Pressure Testing – Steering Pump
Pressure Testing – Steering Pump
1 Park the machine on firm, level ground and apply the parking brake. Jack up the front of the machine until the wheels are clea…
1 Park the machine on firm, level ground and apply the parking brake. Jack up the front of the machine until the wheels are clea…
2 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point
Jacking
A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of t…
2 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point
Y
<GRAPHIC
<GRAPHIC
418540-C1
Fig 3.
3 Fit a 30 mm lock stop (part number 476/40702) at the left-hand side.
4 Run engine at 1500 rev/min, turn the steering wheel to full left lock and hold while checking the gauge reading against the pressure given in Technical Data.
5 If the gauge reading is not correct, the fault is likely to be in the pump relief valve which should be removed for cleaning (see
Section E
6 If after cleaning the pressure is still not correct it can be adjusted, but the pressure MUST NOT under any circumstances be set higher than the setting given in Technica Data. Proceed as follows:
K Fig 4. ( T H1-9) The pressure setting is controlled by an adustable relief valve cartridge located in the pump end cover (shown at
K Fig 4. ( T H1-9)
X
a Make sure that the engine cannot be started. Remove the retaining cover
a Make sure that the engine cannot be started. Remove the retaining cover
1
2
b Grip the cartridge and turn the adjusting screw
3
c Replace the cartridge and refit the retaining cap
1
2
1
d Start the engine and check the pressure setting. If further adjustment is required stop the engine and repeat the above from step ‘a’.
Table 3. Torque Settings
Table 3. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1
30 – 35
3.0 – 3.5
22 – 26
<GRAPHIC
<GRAPHIC
A1122-C1
Fig 4.
Limit Valve Setting
Limit Valve Setting
K Fig 6. ( T H1-11) In the event of altering wheel width and lock stop sizes, fitting a new steering box or if the adjusting screws
K Fig 6. ( T H1-11)
E
F
1 Park the machine on firm, level ground and apply the parking brake. Jack up the front of the machine until the wheels are clea…
1 Park the machine on firm, level ground and apply the parking brake. Jack up the front of the machine until the wheels are clea…
2 Check that the correct lock stop
D
3 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point
Jacking
A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of t…±
3 Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to test point
Y
<GRAPHIC
<GRAPHIC
418540-C1
Fig 5.
4 Run the engine until the temperature of the oil in the hydraulic tank is at least 20 ˚C and then set the speed to 1500 rpm.
<GRAPHIC
<GRAPHIC
C097060
Fig 6.
5 Turn the steering to full left lock. Set the pressure to 38- 40 bar (550-580 lbf/in
2
E
X
6 Release the steering wheel and turn it back and forth (fully onto left lock 5 times and onto right lock at least once) then re…
7 Turn the steering to full right lock and repeat steps 4 and 5, reading right lock instead of left lock and viceversa. Adjust rear limit valve screw
Due to the proximity of engine revolving parts and the possibility of getting trapped between the wheel and the chassis, rear li…
7 Turn the steering to full right lock and repeat steps 4 and 5, reading right lock instead of left lock and viceversa. Adjust rear limit valve screw
F
8 Once the pressure settings have been completed, remove the lock stops
D
Wheel Alignment
Wheel Alignment
For the wheel alignment procedure refer to
Section 3, Routine Maintenance
Steering Box
Steering Box
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Operation Overview ( T H2-2)
K Operation Overview ( T H2-2)
<TABLE ROW
K Removal and Replacement ( T H2-3)
K Removal and Replacement ( T H2-3)
<TABLE ROW
K Dismantling and Assembly ( T H2-5)
K Dismantling and Assembly ( T H2-5)
<TABLE ROW
Operation Overview
Operation Overview
<GRAPHIC
<GRAPHIC
A161504-B1
Fig 1.
The steering box incorporates pressure limit valves
E
F
Removal and Replacement
Removal and Replacement
K Fig 3. ( T H2-7)
K Fig 3. ( T H2-7)
Before assuming that the steering box is the cause of a steering problem, ensure that all other steering system faults have been rectified (see
Steering SYSTEM
Remove the cooling pack to gain access to the top of the steering box.
The numerical sequence shown on the illustration is intended as a guide to removal.
For replacement the sequence should be reversed.
When Removing
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
When Removing
Do not weld, hammer or apply heat to the drop arm or its shaft. These actions will cause weakness and may result in steering failure.
When Removing
When Removing
Note the positions of index marks
The drop arm will be very tight on the splines. Take great care when pulling off the arm as it is likely to be released suddenly with considerable force.
Note the positions of index marks
X
Y
Use a suitable ball joint splitter when removing drag link
5
Do not disturb the length adjustment of drag link
5
Use puller adapters
A
B
6
Before disconnecting pipes, label them to assist correct refitting. Blank the open ports to prevent loss of oil and entry of dirt.
When Replacing
When Replacing
It is absolutely critical that the steering box mounting bolts are tightened to the torque setting specified below. Failure to do this may result in erratic steering.
Before fitting pinch bolt
9
Steering Shafts
After fitting pipework and before fitting drop arm, purge air from the hydraulic system by turning the steering wheel from lock to lock 3 times and then back to straight ahead (with engine running at idle).
When fitting drop arm, align marks
X
Y
Tighten drag link nut
4
After fitting the steering box, ensure that lock limit valves are correctly set, see
Steering SYSTEM
Table 1. Torque Settings
Table 1. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1
1
16 – 18
1.7 – 2.0
12 – 15
<TABLE ROW
2
2
915
93
675
<TABLE ROW
4
4
135
13.7
100
<TABLE ROW
9
9
75
7.6
55
<TABLE ROW
10
Torque value for Dacromet fastners, coloured mottled silver
500
51
370
<GRAPHIC
<GRAPHIC
S301830-C1
Fig 2.
Dismantling and Assembly
Dismantling and Assembly
K Fig 3. ( T H2-7)
K Fig 3. ( T H2-7)
The numerical sequence shown on the illustration is intended as a guide to dismantling.
For assembly the sequence should be reversed.
Input seals
43
44
40
42
When Dismantling
When Dismantling
Remove screws
10
11
Steering SYSTEM
When cover
2
5
With the steering box positioned so that ball retainer cap
17
X
When the piston is out of the housing, remove cap
17
18
31
21
Do not remove plugs
C
D
Renewal of rotary valve seals
25
To renew input shaft seals
35
36
27
37
Special spanners will be required to tighten star nut
27
28
To allow star nut
27
The gear is secured to the sector shaft
5
39
38
When Assembling
When Assembling
Remove any burrs from the piston using a fine hand stone.
Apply a light coat of grease to the seals, thrust bearings and thrust washers.
When fitting shaft seal
36
35
When renewing seals
25
26
25
W
Fit the shaft nut, star nut and check bearing preload as detailed on the next page.
When fitting new seals to the piston, position back-up ‘O’ ring
23
22
If shortage of time does not allow sufficient contraction of the seal, use a suitable piston ring clamp to compress the seal.
Enter the piston
20
Enter the input shaft into the piston so that the bearing cap
37
20
Y
Z
18
17
When sliding the piston through the housing bore, take care to avoid damaging seals as they pass the edges of the housing bore for sector shaft
Do not turn the steering wheel to the left with a 0 – 40 bar pressure gauge connected. Doing this would damage the gauge due to the high pressure at the test point during a left turn.
When sliding the piston through the housing bore, take care to avoid damaging seals as they pass the edges of the housing bore for sector shaft
5
Install the sector shaft so that the timing mark on the sector shaft gear tooth aligns with the timing mark on the piston rack. Tap the end of the sector shaft with a soft hammer to ensure full tooth engagement.
Table 2. Torque Settings
Table 2. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1
1
249 – 263
24.8 – 26.8
184 – 19
<TABLE ROW
12
12
72 – 85
7.3 – 8.6
53 – 63
<TABLE ROW
16
16
249 – 263
125.4 – 26.8
184 – 190
<GRAPHIC
<GRAPHIC
S222451A-C1
Fig 3.
Fitting the Input Shaft Nut and Star Nut
Fitting the Input Shaft Nut and Star Nut
1 Ensure that the input shaft, thrust bearings and thrust washers are correctly installed in the positons shown on the assembly illustration. Using spanner
1 Ensure that the input shaft, thrust bearings and thrust washers are correctly installed in the positons shown on the assembly illustration. Using spanner
A
<GRAPHIC
<GRAPHIC
222460-B1
Fig 4.
2 Fit a new star nut
27
A
B
Do not use the threaded hole in the bearing cap. This is for the lock limit screw.
Turn the bearing cap over in the vice. Rotate the splined end of the shaft using a torque meter and a suitable socket. The reading should be less than 2.8 Nm (2 lbf ft). If this figure is exceeded, re-check the torque on the shaft nut.
<GRAPHIC
<GRAPHIC
222470-B1
Fig 5.
3 Bend two tangs of the star nut into the two plain holes in the bearing cap as at
C
Stake the star nut into the shaft nut at the two notches
D
<GRAPHIC
<GRAPHIC
222480-B1
Fig 6.
Steering Shafts
Steering Shafts
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Inspection ( T H3-2)
K Inspection ( T H3-2)
<TABLE ROW
K Universal Joints and Phasing ( T H3-2)
K Universal Joints and Phasing ( T H3-2)
<TABLE ROW
K Intermediate Shafts and Bearings ( T H3-2)
K Intermediate Shafts and Bearings ( T H3-2)
<TABLE ROW
K Bulkhead Shaft ( T H3-3)
K Bulkhead Shaft ( T H3-3)
Inspection
Inspection
<GRAPHIC
<GRAPHIC
C097110
Fig 1.
Universal Joints and Phasing
Universal Joints and Phasing
Check for stiff (seized) or worn universal joints (UJ)
1
It is important that high pressure water jets are not pointed at universal joints during cleaning. The universal joints have grease nipples which should be greased if steering becomes stiff or if a new shaft is fitted.
Shafts with worn or seized unversal joints must be replaced.
The phasing of the shaft universal joints is fixed by means of location slots
2
3
When installing shafts make sure bearing grub screws
5
4
6
5
Intermediate Shafts and Bearings
Intermediate Shafts and Bearings
If the steering wheel does not turn smoothly inspect the bearings
7
If necessary remove the shafts together their bearings to help determine which bearing is defective.
Table 1. Torque Settings
Table 1. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
4
37
3.8
27
<TABLE ROW
4A
4A
75
7.6
55
Bulkhead Shaft
Bulkhead Shaft
Replace the bulkhead shaft
1
6
1 Remove the dash board shroud.
1 Remove the dash board shroud.
2 Remove clamp bolt
5
6
3 Uncouple the sliding shaft at the opposite end of shaft assembly
1
4 Remove four bolts
2
<GRAPHIC
<GRAPHIC
C097140
Fig 2.
When replacing:
– Seal the shaft plate
– Seal the shaft plate
1
– Align the shaft splines so that the universal joint clamp bolt hole aligns with the slot
3
5
Table 2. Torque Settings
Table 2. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
2
2
22.5
2.3
17
<TABLE ROW
5
37
3.8
27
Page left intentionally blank

SectionS
Section S
Section S
Suspension
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – 3000 XTRA Series Fastrac
Service Manual – 3000 XTRA Series Fastrac
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Hitches and Attachments
Section A – Hitches and Attachments
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Steering
Section H – Steering
<TABLE ROW
Section S – Suspension
Section S – Suspension
<TABLE ROW
Section T – Engine
Section T – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Front Suspension SYSTEM
Front Suspension SYSTEM
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system..
<TABLE ROW
Descriptions and procedures relate to the system and not the individual devices.
<TABLE ROW
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Operation Overview ( T S1-2)
K Operation Overview ( T S1-2)
<TABLE ROW
K Removal and Replacement – Shock Absorber (D) ( T S1-3)
K Removal and Replacement – Shock Absorber (D) ( T S1-3)
<TABLE ROW
K Removal and Replacement – Control Arm (A) ( T S1-4)
K Removal and Replacement – Control Arm (A) ( T S1-4)
<TABLE ROW
K Removal and Replacement – Panhard Rod (B) ( T S1-7)
K Removal and Replacement – Panhard Rod (B) ( T S1-7)
<TABLE ROW
K Removal and Replacement – Anti Roll Bar (E) ( T S1-9)
K Removal and Replacement – Anti Roll Bar (E) ( T S1-9)
<TABLE ROW
K Removal and Replacement – Coil Spring and Microcellular Spring ( T S1-11)
K Removal and Replacement – Coil Spring and Microcellular Spring ( T S1-11)
Operation Overview
Operation Overview
The front axle is located by a four link system consisting of three control arms
A
B
Primary suspension stiffness is provided by coil springs
C
Suspension movement is controlled by two telescopic shock absorbers
D
E
<GRAPHIC
<GRAPHIC
714751-C1
Fig 1.
Removal and Replacement – Shock Absorber (D)
Removal and Replacement – Shock Absorber (D)
The numerical sequence shown on the illustration (items
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration (items
D1
D12
For Replacement the sequence should be reversed.
Note: This job can be done with the machine standing on its wheels.
When Replacing
When Replacing
When fitting the mounting pin
D12
Table 1. Torque Settings
Table 1. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
D1
D1
180
18.4
133
<TABLE ROW
D3
D3
180
18.4
133
<TABLE ROW
D12
D12
300
31
220
<GRAPHIC
<GRAPHIC
714740-C1
Fig 2.
Removal and Replacement – Control Arm (A)
Removal and Replacement – Control Arm (A)
K Fig 3. ( T S1-6)
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
K Fig 3. ( T S1-6)
K Fig 3. ( T S1-6)
View V opposite shows the front end of the two outer control arms. View
W
X
Y
When Removing
When Removing
Just support the weight of the chassis by means of axle stands beneath the lower control arm chassis mount cross member.
If more than one arm is to be removed it is also necessary to support the axle on stands, so as to maintain its location relative to the chassis.
When Replacing
When Replacing
Tighten all bolts and nuts to the specified torque with the machine standing on its wheels.
Outer Control Arms
Outer Control Arms
K Fig 3. ( T S1-6)
K Fig 3. ( T S1-6)
Removal
Removal
Support the control arm and remove nut
A6 (V)
A3 (Y)
Replacement
Replacement
Replacement is the reverse of Removal.
Centre Control Arm
Centre Control Arm
K Fig 3. ( T S1-6)
K Fig 3. ( T S1-6)
Removal
Removal
Support the control arm. At the front end, loosen nut
A4 (W)
A5 (W)
A1
A2 (X)
Separate the control arm from mounting block
E
A4
Replacement
Replacement
Install the control arm taper in mounting block E and loosely fit nut
A4
A5
A4
A4
A1
A2 (X)
Table 2. Torque Settings
Table 2. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
A4 (W)
A4 (W)
Torque value for Dacromet fastners, coloured mottled silver
Centre arm – front
1400
143
1033
<TABLE ROW
A5
A5
647
67
482
<TABLE ROW
A6 (V)(1)
A6 (V)
(1)
Side Arms – front
250
26
184
<TABLE ROW
A1/A2 (X)(1)
(1)
Center arm – rear
559
57
412
<TABLE ROW
A3 (Y)(1)
A3 (Y)
(1)
Side arms – rear
250
26
184
Control Arm Bosses (View Y)
Control Arm Bosses (View Y)
K Fig 3. ( T S1-6)
K Fig 3. ( T S1-6)
Removal and Replacement
Removal and Replacement
1 Check the torque of the four bolts
1 Check the torque of the four bolts
U
T
2 Clean the mating surfaces of the chassis and the control arm boss down to bare metal using a medium grade emery cloth to produce the final surface finish.
3 Refit the boss to the chassis using bolts
U
V
W
<GRAPHIC
<GRAPHIC
714720-C1
Fig 3.
Removal and Replacement – Panhard Rod (B)
Removal and Replacement – Panhard Rod (B)
K Fig 4. ( T S1-8)
K Fig 4. ( T S1-8)
The numerical sequence shown on the illustration (items
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration (items
B1
B6
For assembly the sequence should be reversed.
This job can be done with the machine standing on its wheels.
When Removing
When Removing
Separate the taper ball pins from their brackets using a ball joint splitter.
When Replacing
Do not hammer the cast iron lugs on the axle as this will cause weakness and may lead to steering failure.
When Replacing
When Replacing
Before fitting, check dimension
X
Y
B5
Y
Tighten nuts
B2
B4
After fitting the Panhard rod, recheck adjustment by measuring the distance between the top of each front wheel rim and the chas…
100 hours after fitting the Panhard rod, check the torque tightness of nuts
B2
B4
Table 3. Torque Settings
Table 3. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
B2/B4
244
25
180
<TABLE ROW
Y
Y
70 – 80
7.1 – 8.2
52 – 59
<GRAPHIC
<GRAPHIC
714710-C2
Fig 4.
Removal and Replacement – Anti Roll Bar (E)
Removal and Replacement – Anti Roll Bar (E)
K Fig 5. ( T S1-10)
K Fig 5. ( T S1-10)
The numerical sequence shown on the illustration (items
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration (items
E1
E8
For assembly the sequence should be reversed.
This job can be done with the machine standing on its wheels.
When Removing
When Removing
Remove nuts
E1
E2
E3
E4
E6
E7
E8
When Replacing
When Replacing
Renew sleeves
E8
Do not overtighten nuts
E1
E2
Table 4. Torque Settings
Table 4. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
E1/E2
Torque value for Dacromet fastners, coloured mottled silver
200
20
148
<TABLE ROW
E3/E4
E3/E4
47.5
4.8
35
<GRAPHIC
<GRAPHIC
714710-C1
Fig 5.
Removal and Replacement – Coil Spring and Microcellular Spring
Removal and Replacement – Coil Spring and Microcellular Spring
K Fig 6. ( T S1-12)
K Fig 6. ( T S1-12)
Removal
Removal
The coil spring
C
G2
Raise both sides of the machine equally by one of the following methods:
1 Use an overhead hoist to raise front of chassis (minimum lift capacity for basic machine is 3.5 tonnes or 5 tonnes with optional equipment). Lift until front wheels are about to clear the ground.
This component is heavy. It must only be removed or handled using a suitable lifting method and device.
1 Use an overhead hoist to raise front of chassis (minimum lift capacity for basic machine is 3.5 tonnes or 5 tonnes with optional equipment). Lift until front wheels are about to clear the ground.
1 Use an overhead hoist to raise front of chassis (minimum lift capacity for basic machine is 3.5 tonnes or 5 tonnes with optional equipment). Lift until front wheels are about to clear the ground.
2 Insert a piece of timber 50 x 50 mm ( 2 x 2 in) between the axle and each bump stop as at
X
Remove bolt
G1
G2
G3
Pry out coil spring
C
G2
G3
Unscrew the microcellular spring from the spacer.
Keep your hands clear of the springs until they have been released and are no longer under load or you may trap your fingers.
Unscrew the microcellular spring from the spacer.
Replacement
Replacement
Reverse the dismantling sequence.
Tighten the microcellular spring onto the spacer using hand pressure only.
Table 5. Torque Settings
Table 5. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
G1
392
40
289
<GRAPHIC
<GRAPHIC
714700-C1
Fig 6.
Rear Suspension SYSTEM
Rear Suspension SYSTEM
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine SYSTEM. The system has some devices that connect either mechanically, hydraulically or electrically. Make sure you are referring to the correct system.
<TABLE ROW
Descriptions and procedures relate to the system and not the individual devices.
<TABLE ROW
This topic is intended to help you understand what the system does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Technical Data ( T S2-2)
K Technical Data ( T S2-2)
<TABLE ROW
K Operation Overview ( T S2-3)
K Operation Overview ( T S2-3)
<TABLE ROW
K Primary System ( T S2-3)
K Primary System ( T S2-3)
<TABLE ROW
K Ride Height Control ( T S2-4)
K Ride Height Control ( T S2-4)
<TABLE ROW
K Ride Height Calibration ( T S2-6)
K Ride Height Calibration ( T S2-6)
<TABLE ROW
K Testing ( T S2-8)
K Testing ( T S2-8)
<TABLE ROW
K Pressure Maintenance Valve ( T S2-8)
K Pressure Maintenance Valve ( T S2-8)
<TABLE ROW
K Accumulator and Gas Spring ( T S2-9)
K Accumulator and Gas Spring ( T S2-9)
<TABLE ROW
K Discharging the Hydraulic Pressure ( T S2-10)
K Discharging the Hydraulic Pressure ( T S2-10)
<TABLE ROW
K Removal and Replacement – Potentiometer ( T S2-12)
K Removal and Replacement – Potentiometer ( T S2-12)
<TABLE ROW
K Removal and Replacement – Accumulator (A), Gas Spring (G) ( T S2-13)
K Removal and Replacement – Accumulator (A), Gas Spring (G) ( T S2-13)
<TABLE ROW
K Removal and Replacement – Anti-roll Bar ( T S2-15)
K Removal and Replacement – Anti-roll Bar ( T S2-15)
<TABLE ROW
K Removal and Replacement – Control Arm (J) ( T S2-16)
K Removal and Replacement – Control Arm (J) ( T S2-16)
<TABLE ROW
K Removal and Replacement – ‘V’ Link ( T S2-18)
K Removal and Replacement – ‘V’ Link ( T S2-18)
<TABLE ROW
K Removal and Replacement – Suspension Cylinder (S) ( T S2-21)
K Removal and Replacement – Suspension Cylinder (S) ( T S2-21)
<TABLE ROW
K Dismantling and Assembly – Suspension Cylinder ( T S2-23)
K Dismantling and Assembly – Suspension Cylinder ( T S2-23)
<TABLE ROW
Technical Data
Technical Data
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Pump
Pump
<TABLE ROW
Type
Front section (P1) of gear type pump, driven by engine.
<TABLE ROW
Maximum flow
36.5 litres/min (8.0 UK gal/min, 9.6 US gal/min)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Pressures
Pressures
bar
bar
kgf/cm3
kgf/cm
3
lbf/in2
lbf/in
2
<TABLE ROW
Pressure maintaining valve
<TABLE ROW
Cut-out pressure
200
204
2900
<TABLE ROW
Cut-in pressure
180
184
2610
<TABLE ROW
Accumulator charge pressure
75
76.5
1087
<TABLE ROW
Gas spring charge pressure
35
36
508
Operation Overview
Operation Overview
Primary System
Primary System
<GRAPHIC
<GRAPHIC
C095690
Fig 1.
The variable rate hydropneumatic rear suspension minimises fore and aft vehicle pitch whilst maintaining ‘low rate’ characteristics for ride quality and tractive performance.
Axle location is by control rods
J
L
K
Primary suspension comprises two nitrogen-charged gas springs
F
G
Movement of the axle varies the pressure in the cylinders which in turn works against the pressure in the gas springs to give a variable rate suspension.
Ride Height Control
Ride Height Control
The rear axle has an automatic ride height control system. The system is controlled by the central control ECU (ECU1). The ECU controls the ride height by energising or de-energising hydraulic solenoid valves
CT8
9
10
11
C
Hydraulic pressure is provided by section P2 of the engine driven hydraulic pump. The solenoid control valve block
V
CT1
A
When increasing loads cause the chassis to lower in relation to the rear axle. When the axle control rods
J
C
D
CT8
CT10
F
G
As the load is taken off the chassis, it is lifted by the pressure retained in the system. This action once again displaces the potentiometers, but in the opposite direction, and the ECU energises solenoid valves
CT9
CT11
The reducing pressure allows the chassis to settle until the potentiometers reach the pre-set ride height position. The ECU then de-energises the solenoid valves retaining the new volume of oil in the system.
The height control system is not affected by normal suspension movements which are too rapid for the in-built response delay time.
K Hydraulic Schematic ( T S2-5)
K Hydraulic Schematic ( T S2-5)
<GRAPHIC
<GRAPHIC
C095700
Fig 2.
Table 1. Solenoid Valve Function
Table 1. Solenoid Valve Function
<TABLE
<TABLE HEADING
<TABLE ROW
Suspension Cylinder
Raise Solenoid Valve
Lower Solenoid Valve
<TABLE BODY
<TABLE ROW
Left Hand
CT8
CT9
<TABLE ROW
Right Hand
CT10
CT11
<GRAPHIC
<GRAPHIC
C095740
Fig 3. Hydraulic Schematic
Ride Height Calibration
Ride Height Calibration
Calibration is necessary after replacement of any of the following:
– Suspension potentiometer (angle sensor).
– Suspension potentiometer (angle sensor).
– Suspension potentiometer operating link
– Lower suspension link (control arm)
– ECU1 (Fastrac Central Controller)
Be aware that this process is time critical – read the following steps before you start.
If at any point during calibration, the instrument panel displays `FAILED’, note which stage it was at, exit from calibration and use the Service Master Datalog tool to retrieve the error codes from the error log.
<GRAPHIC
<GRAPHIC
<GRAPHIC
C090110-C1
Fig 4.
1 Apply the park brake.
2 Make sure the transport switch
T
3 Switch the Ignition `ON’.
4 As the first instrument panel buzzer has finished sounding and within 10 seconds after you have switched on the ignition, cycle the transport switch on and off twice.
The instrument panel will display `SUSP CAL’ for a short time.
5 Start the engine when the instrument panel displays `START’.
5 Start the engine when the instrument panel displays `START’.
<GRAPHIC
The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab.
<GRAPHIC
<GRAPHIC
403731-C1
Fig 5.
6 When `RS RAISE’ is displayed, press and hold in button
C
C
If the suspension is fully down on the bump stops, there may be a delay before the suspension starts to raise.
7 Place blocks, 65mm (2.6 in) thick btween the rear axle and bump stops at X. This should give an axle ride height of 50mm (2 in) with a 15mm (0.6 in) allowance for bump stop compression during calibration.
<GRAPHIC
Keep clear of the chassis members as they are lowering otherwise you could be trapped between them and the axle casing.
<GRAPHIC
<GRAPHIC
C039350-B6
Fig 6.
8 Use down arrow
D
<GRAPHIC
<GRAPHIC
C096040
Fig 7.
9 Press button
C
Button C is located at one of two positions.
10 The instrument panel will display the position of the rear suspension in the following format:
`
LxxxRyyy
The actual figures `xxx’ indicate the left hand suspension height signal.
The actual figures `yyy’ indicate the right hand suspension height signal. These can also be monitored in JCB Service Master.
11 Let the rear suspension settle fully onto the bump stops. When the suspension appears to have stopped moving, leave it 30 seconds more to make sure it has fully settled.
12 Press button
C
The instrument panel will display `OK’ if the calibration values are acceptable.
If the instrument panel displays `FAILED’, a fault code will appear on the touch screen.
13 Use arrow
D
14 Press and hold in button
C
15 Remove the blocks from between the rear axle and the bump stops.
16 Scroll down to `SAVE’.
17 Press button
C
18 The system will now exit calibration mode.
Testing
Testing
Pressure Maintenance Valve
Pressure Maintenance Valve
Connect a 0-400 bar (0 – 6000 lbf/in
The procedure below must be carried out with the engine running. Apply the park brake, block the wheels and ensure that no-one enters the cab.
Connect a 0-400 bar (0 – 6000 lbf/in
2
TP1
With engine running, push up one of the potentiometer operating links and check the gauge reading which should be between the cut-in and cut-out pressures.
K Technical Data ( T S2-2)
If the reading is incorrect, adjust the valve at
CT1
If this is the first time the valve has been adjusted, the adjusting screw will be covered by a plastic cap which should be removed and discarded.
<GRAPHIC
<GRAPHIC
C096910
Fig 8.
Accumulator and Gas Spring
Accumulator and Gas Spring
Gas spring and accumulator are similar in appearance but can be positively identified by the nominal pressure (bar) stamped on the body near boss
B
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
26 or 35
Indicates gas spring. K Technical Data ( T S2-2)
K Technical Data ( T S2-2)
<TABLE ROW
75
Indicates accumulator
Remove the gas spring
G
A
X
Connect a hand pump and a 0 to 400 bar (0 to 6000 lbf/in
2
Operate the hand pump and watch the reading on the gauge.
If the gas spring or accumulator is in good condition, the pressure should rise steadily to the charge pressure, see Technical Data) and then rise much more slowly for a period before climbing again.
If the pressure continues to rise steadily to well past the charge pressure, the diaphragm is ruptured and the unit must be renewed.
<GRAPHIC
<GRAPHIC
162220-B1
Fig 9.
Discharging the Hydraulic Pressure
Discharging the Hydraulic Pressure
The chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve.
Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure.
Be aware that this process is time critical – read the following steps before you start.
1 Make sure the transport switch
1 Make sure the transport switch
T
<GRAPHIC
<GRAPHIC
C090110-C1
Fig 10.
2 Apply the park brake.
3 Switch the Ignition `On’.
4 As the first instrument panel buzzer has finished sounding and within 10 seconds after you have switched on the ignition, cycle the transport switch on and off twice.
The instrument panel will display `SUSP CAL’ for a short time.
5 When the instrument panel displays `START’,
DO NOT START THE ENGINE
6 Press down arrow
D
C
7 Use down arrow
D
<GRAPHIC
<GRAPHIC
C039350-B6
Fig 11.
<GRAPHIC
<GRAPHIC
C096040
Fig 12.
8 Press button
Keep clear of the chassis members as they are lowering otherwise you could be trapped between them and the axle casing.
8 Press button
C
Button C is located at one of two positions.
9 When the suspension has lowered fully, press button
U
10 Hold in button
C
11 Use down arrow
D
12 Press button
C
13 When the suspension has lowered fully, press button
U
14 Hold in button
C
15 Use down arrow
D
16 Press button
C
17 When the suspension has lowered fully, switch off the ignition.
Removal and Replacement – Potentiometer
Removal and Replacement – Potentiometer
This job can be done with the machine standing on its wheels but wooden blocks should be placed between chassis and rear axle to prevent the possibility of the ride height dropping while the potentiometer is removed.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
This job can be done with the machine standing on its wheels but wooden blocks should be placed between chassis and rear axle to prevent the possibility of the ride height dropping while the potentiometer is removed.
<GRAPHIC
<GRAPHIC
C095760
Fig 13.
Removal
Removal
1 Disconnect the electrical connector at
1 Disconnect the electrical connector at
A
2 Remove nut
B
E
3 Remove bolts
C
4 Remove the potentiometer
D
Replacement
Replacement
Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:
– Be sure to put the operating link in the correct location on the potentiometer actuator arm
– Be sure to put the operating link in the correct location on the potentiometer actuator arm
G
– Be sure that the length of operating link is correct. If necessary loosen lock nuts
F
F
After Replacement
After Replacement
Calibrate the suspension.
K Ride Height Calibration ( T S2-6)
Removal and Replacement – Accumulator (A), Gas Spring (G)
Removal and Replacement – Accumulator (A), Gas Spring (G)
This job can be done with the machine standing on its wheels but heed the WARNINGS below.
The numerical sequence shown on the illustration is intended as a guide to removal.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration is intended as a guide to removal.
The rear of the chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve.
Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. See Discharging Hydraulic Pressure (Section S) for correct procedure.
The numerical sequence shown on the illustration is intended as a guide to removal.
For replacement the sequence should be reversed.
When Removing Gas Spring or Accumulator
When Removing Gas Spring or Accumulator
Simply unscrew the unit from its mounting (complete with square section seal ring). Renew the seal when refitting the unit.
Gas spring and accumulator are similar in appearance but can be positively identified by the nominal pressure (bar) stamped on the face of the threaded mounting boss: 26 or 35 indicates gas spring (see
Technical Data
After Replacing
After Replacing
Check the suspension ride height.
K Ride Height Calibration ( T S2-6)
Table 2. Torque Settings
Table 2. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
A
23 – 30
2.4 – 3.0
17 – 22
<TABLE ROW
G
23 – 30
2.4 – 3.0
17 – 22
<GRAPHIC
<GRAPHIC
403710-C2
Fig 14.
Removal and Replacement – Anti-roll Bar
Removal and Replacement – Anti-roll Bar
This job can be done with the machine standing on its wheels.
The numerical sequence shown on the illustration is intended as a guide to removal. The illustrations depict only the left end of the anti-roll bar, but the appropriate steps should be repeated immediately afterwards on the right end of the bar.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration is intended as a guide to removal. The illustrations depict only the left end of the anti-roll bar, but the appropriate steps should be repeated immediately afterwards on the right end of the bar.
Replacement is the reverse of Removal.
When Replacing
When Replacing
Assemble all the component parts of the assembly before tightening up the nuts and bolts which actually support the anti-roll bar.
Install clamps
K10
Finally, before tightening nuts
K8
K9
K10
K5
Table 3. Torque Settings
Table 3. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
K1/K2
K1/K2
Torque value for Dacromet fastners, coloured mottled silver
278
28
205
<TABLE ROW
K3(1)
(1)
80
8.2
59
<TABLE ROW
K8/K9(1)
(1)
22.5
2.3
16.6
<TABLE ROW
K12(1)
K12
(1)
100
10
72
<TABLE ROW
K15/K16(1)
K15/K16
(1)
392
40
289
<GRAPHIC
<GRAPHIC
S293360-C1
Fig 15.
Removal and Replacement – Control Arm (J)
Removal and Replacement – Control Arm (J)
This job can be done with the machine standing on its wheels but the rear wheels must be chocked to maintaing axle location..
Remove the anti-roll bar first.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
Remove the anti-roll bar first.
The numerical sequence
J1
J8
For replacement the sequence should be reversed.
When Removing
When Removing
Unscrew nuts
J1
J2
J3
J4
J6
J7
Table 4. Torque Settings
Table 4. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
J1
12
1.2
9
<TABLE ROW
J2/J3
Torque value for Dacromet fastners, coloured mottled silver.
278
28
205
<TABLE ROW
J6/J7(1)
(1)
278
28
205
<GRAPHIC
<GRAPHIC
403700-C1
Fig 16.
Removal and Replacement – ‘V’ Link
Removal and Replacement – ‘V’ Link
This job can be done with the machine standing on its wheels but the rear axle must be supported by means of an overhead hoist to prevent it from rotating out of position.
The numerical sequence shown on the illustration is intended as a guide to removal.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration is intended as a guide to removal.
For replacement the sequence should be reversed.
When Removing
When Removing
Support axle and ‘V’ link
L
Remove bolts
1
2
Remove flange nuts
3
4
5
6
When Replacing
When Replacing
Always replace damaged fasteners by the specified JCB supplied parts which will be to the correct grade.
Ensure that special bolts
5
6
4
3
5
6
Torque bolts
5
o
Table 5. Torque Settings
Table 5. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1
Torque value for Dacromet fastners, coloured mottled silver.
395
40
291
<TABLE ROW
5
See text
<GRAPHIC
<GRAPHIC
418450-C1
Fig 17.
Dismantling and Assembly – Ball Joint
Dismantling and Assembly – Ball Joint
The ‘V’ link ball joint should not be dismantled unless wear is detected. Items
1
9
11
12
Item
9
5
10
The numerical sequence shown on illustration
X
For assembly the sequence should be reversed.
When Dismantling
When Dismantling
Cover
1
10
To separate the taper which connects items
8
13
8
Y
When Assembling
When Assembling
When assembling items
1
8
9
10
12
To secure item
1
Table 6. Torque Settings
Table 6. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
6
135
13.7
99
<GRAPHIC
<GRAPHIC
A243370-C1
Fig 18.
Removal and Replacement – Suspension Cylinder (S)
Removal and Replacement – Suspension Cylinder (S)
This job can be done with the machine standing on its wheels but heed the WARNINGS below.
The numerical sequence shown on the illustration is intended as a guide to removal.
Make the machine safe before getting beneath it. Park the machine on level ground and lower the attachments. Stop the engine and…
The numerical sequence shown on the illustration is intended as a guide to removal.
The rear of the chassis is supported by suspension components which are charged with pressurised hydraulic fluid when the engine is running. When the engine is stopped, pressure is trapped in components downstream of the check valve.
Before disconnecting pipework or removing hydraulic components, the chassis must be lowered to discharge the pressure. See Discharging Hydraulic Pressure (Section S) for correct procedure.
The numerical sequence shown on the illustration is intended as a guide to removal.
For replacement the sequence should be reversed.
When Removing
When Removing
Disconnect hose at
S1
S2
S3
S4
S5
After Replacing
After Replacing
Lugs
Z
<GRAPHIC
<GRAPHIC
S268400-C1
Fig 19.
Check the suspension ride height.
K Ride Height Calibration ( T S2-6)
Table 7. Torque Settings
Table 7. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
Kgf m
lbf ft
<TABLE BODY
<TABLE ROW
S2
50
5.0
37
<TABLE ROW
S6
Torque setting is for use when fitting the pin to the axle.
800
81
592
<GRAPHIC
<GRAPHIC
403710-C1
Fig 20.
Dismantling and Assembly – Suspension Cylinder
Dismantling and Assembly – Suspension Cylinder
Machines can be fitted with either damped or undamped suspension cylinders. The external parts shown at
A
B
C
The numerical sequence shown on the illustration is intended as a guide to dismantling.
For assembly the sequence should be reversed.
Take extreme care not to damage the cylinder bore.
When Dismantling
When Dismantling
Remove grease nipple 1 and prise off the dust cover 2 in the direction of the arrow.
Heat the threaded area of gland bearing
3
4
Withdraw the piston rod
18
B
C
On undamped cylinders, remove circlip
5B
3
On damped cylinders, heat the threaded area of seal carrier
5C
W
3
6
9
10
12
When Assembling
Before assembling, check the components for damage and wear, especially the cylinder bore. Renew the complete assembly if necessary. Lightly oil all seals. Use the procedure right for fitting gland seals
6
8
<GRAPHIC
<GRAPHIC
A234821-C1
Fig 21.
Testing
Testing
Using a hydraulic hand pump (see
Service Tools, Section 1
With the ram extended, pressurise to 250 bar (3625 lbf/in
2
Gland Fitting Procedure
Gland Fitting Procedure
The size (diameter) and position of pins
D
The pins are screwed into threaded holes in the tool body. The spacing of the holes is designed to suit small or large diameter gland seals.
To fit new gland seals
6
8
1 Open the tool as shown at
1 Open the tool as shown at
X
2 Close the tool as shown at
Y
E
Z
<GRAPHIC
<GRAPHIC
S161750-C2
Fig 22.
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SectionT
Section T
Section T
Engine
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – 3000 XTRA Series Fastrac
Service Manual – 3000 XTRA Series Fastrac
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Routine Maintenance
Section 3 – Routine Maintenance
<TABLE ROW
Section A – Hitches and Attachments
Section A – Hitches and Attachments
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section F – Transmission
Section F – Transmission
<TABLE ROW
Section G – Brakes
Section G – Brakes
<TABLE ROW
Section H – Steering
Section H – Steering
<TABLE ROW
Section S – Suspension
Section S – Suspension
<TABLE ROW
Section T – Engine
Section T – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Cummins QSB 6.7
Cummins QSB 6.7
Introduction
Introduction
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device.
<TABLE ROW
Descriptions and procedures relate to the device and not related systems.
<TABLE ROW
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes procedures such as removal and replacement and dismantle and assemble.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Technical Data ( T T1-2)
K Technical Data ( T T1-2)
<TABLE ROW
K Removal and Replacement – Flywheel Damper ( T T1-3)
K Removal and Replacement – Flywheel Damper ( T T1-3)
<TABLE ROW
K Dismantling and Assembly ( T T1-4)
K Dismantling and Assembly ( T T1-4)
Technical Data
Technical Data
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Engine Model
QSB 6.7, 6-cylinder
Turbocharged, charge air cooled.
<TABLE ROW
<TABLE ROW
Swept Volume
6702 cm3
3
(409 in3)
3
<TABLE ROW
<TABLE ROW
Bore
107 mm
(4.21 in)
<TABLE ROW
<TABLE ROW
Stroke
124 mm
(4.88 in)
<TABLE ROW
<TABLE ROW
Dry Weight
485 kg
(1069 lb)
<TABLE ROW
<TABLE ROW
Firing Order
1, 5, 3, 6, 2, 4
<TABLE ROW
<TABLE ROW
Compression Ratio
17.2 : 1
<TABLE ROW
<TABLE ROW
Valve Clearance
<TABLE ROW
– Inlet
0.31 mm
(0.012 in)
<TABLE ROW
– Exhaust
0.56 mm
(0.022 in)
<TABLE ROW
<TABLE ROW
Oil Pressure at idle
<TABLE ROW
(minimum allowable)
0.52 bar
(7.5 lbf/in2)
2
<TABLE ROW
<TABLE ROW
Oil Pressure, regulated
3.8 bar
(55 lbf/in2)
2
<TABLE ROW
<TABLE ROW
Rated Speed
2200 rev/min
<TABLE ROW
<TABLE ROW
Idling Speed
750 rev/min
<TABLE ROW
<TABLE ROW
Maximum No Load Speed
2520 rev/min
Removal and Replacement – Flywheel Damper
Removal and Replacement – Flywheel Damper
The flywheel damper is a sealed unit. If the damper is faulty it must be renewed. The drive shaft
X
<GRAPHIC
<GRAPHIC
A353530-C1
Fig 1.
Removal
Removal
1 Support the damper assembly
1 Support the damper assembly
1
2
Y
X
2 Retrieve the hardened spacer washers
3
Y
3 Store the damper on its rear face. Do not let the damper rest on the drive shaft
X
Replacement
Replacement
Replacement is the opposite of the removal procedure. During the replacement procedure do this work also:
– Clean the damper assembly. Make sure that the mating faces of the damper and engine flywheel are perfectly clean and dry.
– Clean the damper assembly. Make sure that the mating faces of the damper and engine flywheel are perfectly clean and dry.
– Progressively tighten the bolts
2
Table 1. Torque Settings
Table 1. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
2
72
7.3
53
Dismantling and Assembly
Dismantling and Assembly
For engine dismantling and assembly procedures refer to the correct Cummins technical documentation.
Page left intentionally blank

 

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