JCB Transmissions Service Manual – 9803/8610-14

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JCB Transmissions Service Manual – 9803/8610-14

This service manual PDF download for the JCB Transmissions 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.

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section A – Axle Hubs
Section B – Axle Hubs Swivels and Driveshafts
Section C – Axle Integral Brakes
Section D – Axle Drive Heads
Section E – Manual Gearboxes
Section F – Powershift Gearboxes
Section G – Transfer Gearboxes

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/8610-14
Total Pages : 946

This 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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9803-8610

Section 1 – General Information
General Information
About This Manual
Scope
Axles
Axle Sub-assembly Identification
Applicable Machines
Working Practice
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Service Aids
Sealing and Retaining Compounds

Section 2 – Care and Safety
Care and Safety
Safety Check List
Safety Notices
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety

Section A – Axle Hubs
Axle Hubs
Dead Steer Hub
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Dismantle
Assemble
40 Series Hub
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble
55 and 70 Series Hub
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble
80 Series Hub
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble
80 Series Hub with Integral Brake
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble
85 Series Hub
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble

Section B – Axle Hubs Swivels and Driveshafts
Axle Hubs Swivels and Driveshafts
40 Series Hub Swivel and Driveshaft
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble
55 Series Hub Swivel and Driveshaft
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Sectional Drawing
Dismantle
Assemble
Trunnion Shims
70 Series Driveshaft
Technical Data
Unit Identification
Service Tools
Removal and Replacement
Sectional Drawing
Removal
Replacement
85 Series Driveshaft
Technical Data
Unit Identification
Service Tools
Removal and Replacement
Sectional Drawing
Removal
Replacement

Section C – Axle Integral Brakes
Axle Integral Brakes
40 Series Integral Brakes (3 Piece Axles)
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle and Assemble
Dismantle
Assemble
70 Series Integral Brakes (3 Piece Axles)
Technical Data
Unit Identification
Service Tools
Main Component Identification
Component Key
Dismantle And Assemble
Sectional Drawing
Dismantle
Assemble
85 Series Integral Brakes (3 Piece Axles)
Technical Data
Unit Identification
Service Tools
Dismantle and Assemble
Dismantle
Assemble

Section D – Axle Drive Heads

Section E – Manual Gearboxes
Manual Gearboxes
SS500 Synchro Shuttle
Technical Data
Unit Identification
Service Tools
Main Component Identification
Component Key
Sectional Drawings
Gearbox
Power Take-Off Clutch (if fitted)
Gearbox Dismantle
Gearbox Inspection
Gearbox Assemble
Forward and Reverser Clutch Dismantle
Forward and Reverser Clutch Inspection
Forward and Reverser Clutch Assemble
Power Take Off Clutch
Dismantle
Inspection
Assembly
PTFE Piston Ring Seals – Fitting Procedure
Solenoid Control Valve
Dismantle
Assemble
SS600 Synchro Shuttle
Technical Data
Unit Identification
Service Tools
Main Component Identification
Component Key
Sectional Drawing
Component Key
Gearbox Dismantle
Gearbox Inspection
Gearbox Assembly
Forward and Reverser Clutch Component Identification
Forward and Reverser Clutch Dismantle
Forward and Reverser Clutch Inspection
Forward and Reverser Clutch Assemble
2 and 4 Wheel Drive Clutch Dismantle
2 and 4 Wheel Drive Clutch Inspection
2 and 4 Wheel Drive Clutch Assemble
PTFE Piston Ring Seals Fitting Procedure
Solenoid Control Valve
Dismantle
Assemble
SS700 Synchro Shuttle
Technical Data
Unit Identification
Service Tools
Main Component Identification
Component Key
Sectional Drawing
Component Key
Gearbox Dismantle
Gearbox Inspection
Ring and Cone Synchroniser Unit
Gearbox Assembly
Forward and Reverser Clutch Dismantle
Forward and Reverser Clutch Inspection
Forward and Reverser Clutch Assemble
2 and 4 Wheel Drive Clutch Dismantle
2 and 4 Wheel Drive Clutch Inspection
2 and 4 Wheel Drive Clutch Assemble
PTFE Piston Ring Seals Fitting Procedure
Solenoid Control Valve
Dismantle
Assemble
SS700 Type 2 Synchro Shuttle
Technical Data
Unit Identification
Service Tools
Main Component Identification
Component Key
Sectional Drawing
Component Key
Gearbox Dismantle
Gearbox Inspection
Gearbox Oil Pump
Ring and Cone Synchroniser Unit
Gearbox Assembly
Direct Shift Turret – Dismantle and Assemble
Remote Shift Turret – Dismantle and Assemble
Forward and Reverser Clutch Dismantle
Forward and Reverser Clutch Inspection
Forward and Reverser Clutch Assembly
2 and 4 Wheel Drive Clutch Dismantle
2 and 4 Wheel Drive Clutch Inspection
2 and 4 Wheel Drive Clutch Assembly
PTFE Piston Ring Seals Fitting Procedure

Section F – Powershift Gearboxes
Powershift Gearboxes
PS700 Powershift
Technical Data
Unit Identification
Service Tools
Main Component Identification
Dismantle, Inspection and Assembly
Gearbox
Input Clutch and Reverser Clutch
Mainshaft
Layshaft
PS750 Powershift
Technical Data
Unit Identification
Service Tools
Main Component Identification
Component Key
Dismantle, Inspection and Assembly
Sectional Drawing
Gearbox
Input Clutch (4 Speed Only), Forward and Reverser Clutch
Input Clutch (5 Speed Only)
Layshaft Clutch
Mainshaft Clutch
5th Speed Clutch
2 and 4 Wheel Drive Clutch (4WD Pressure ON)
2 and 4 Wheel Drive Clutch (4WD Spring ON)
Permanent 4 Wheel Drive Unit
PTFE Piston Ring Seals
Solenoid Control Valve
Testing
Pressure Testing the 2 and 4 Wheel Drive Clutch (4WD Spring ON)
PS750 Powershift Mk III
Technical Data
Unit Identification
Service Tools
Dismantle, Inspection and Assembly
Sectional Drawings
Gearbox
Input Clutch, Forward and Reverser Clutch
Layshaft Clutch
Mainshaft Clutch
2 and 4 Wheel Drive Clutch (4WD Pressure ON)
2 and 4 Wheel Drive Clutch (4WD Spring ON)
Permanent 4 Wheel Drive Unit
PTFE Piston Ring Seals
Solenoid Control Valve
Testing
Pressure Testing the 2 and 4 Wheel Drive Clutch (4WD Spring ON)
PS750 Powershift Mk IV
Technical Data
Unit Identification
Service Tools
Main Component Identification
External Components
Internal Components
Dismantling and Assembly
Oil Filter – Removal and Replacement
Removal
Replacement
Suction Strainer – Removal and Replacement
Removal
Replacement
4 Wheel Drive Yoke and Oil Seal – Removal and Replacement
Removal
Replacement
Brake Disc – Removal and Replacement
Removal
Replacement
Solenoid Control Valves – Removal and Replacement
Gearbox Clutch Control Solenoid Valves
2/4WD Clutch Control Solenoid Valve
Torque Converter Relief Valve – Removal and Replacement
Removal
Replacement
Pressure Maintenance Valve – Removal and Replacement
Removal
Replacement
Speed Sensors – Removal and Replacement
Speed Sensor A
Speed Sensor B
Oil Pressure Switch – Removal and Replacement
Removal
Replacement
Oil Pump – Removal, Inspection and Replacement
Removal
Inspection
Replacement
Clutches – Removal
Remove the External Oil Feed Pipe
Separate the Front and Rear Casings
Remove the Clutch Shaft Assemblies
Remove the Oil Transfer Pipe (if fitted)
Clutches – Replacement
Cleaning and Inspection
Install the Oil Transfer Pipe (if fitted)
Install the Clutch Shaft Assemblies
Assemble the Front and Rear Casings
Install the External Oil Feed Pipe
Checking the Clutch Shaft End Floats
Output Shaft and Bearing – Removal and Replacement
Removal
Replacement
Output Shaft Removal – Larger Diameter Gears
Input Clutch, Forward and Reverser Clutch – Dismantle
Dismantle
Input Clutch, Forward and Reverser Clutch – Assemble
Layshaft Clutch – Dismantle
Layshaft Clutch – Assemble
Mainshaft Clutch – Dismantle
Mainshaft Clutch – Assemble
2 and 4 Wheel Drive Clutch (4WD Pressure ON) – Dismantle
2 and 4 Wheel Drive Clutch (4WD Pressure ON) – Assemble
2 and 4 Wheel Drive Clutch (4WD Spring ON) – Dismantle
2 and 4 Wheel Drive Clutch (4WD Spring ON) – Assemble
2 And 4 Wheel Drive Clutch (4WD Spring ON) – Pressure Testing
PTFE Piston Ring Seals
Fitting Procedure
PS766 and PS764 Powershift (2004 on)
Technical Data
Unit Identification
Service Tools
Main Component Identification
Overview
Sectional Drawing
Component Key
Integral Park Brake
Dismantle the Multi Plate Brake Pack
Dismantle the Brake Actuator
Inspection
Assemble the Brake Actuator
Assemble the Multi Plate Brake Pack
Lock Up Torque Converter Control Valve
Removal And Replacement
Gearbox Dismantle
Gearbox Inspection
Gearbox Assembly
Input, Forward and Reverse Clutches – Dismantle
Input, Forward and Reverse Clutches – Inspection
Input, Forward and Reverse Clutches – Assemble
Layshaft Clutch – Dismantle
Layshaft Clutch – Inspection
Layshaft Clutch – Assemble
End Float Setting – Plate Carrier and Gear
Assemble
Mainshaft Clutch – Dismantle
Mainshaft Clutch – Inspection
Mainshaft Clutch – Assemble
6 Speed Clutch – Dismantle
6 Speed Clutch – Inspection
6 Speed Clutch – Assemble
2 and 4 Wheel Drive Clutch (4WD Pressure ON) – Dismantle
2 and 4 Wheel Drive Clutch (4WD Pressure ON) – Inspection
2 and 4 Wheel Drive Clutch (4WD Pressure ON) – Assemble
2 and 4 Wheel Drive Clutch (4WD Spring ON) – Dismantle
2 and 4 Wheel Drive Clutch (4WD Spring ON) – Inspection
2 and 4 Wheel Drive Clutch (4WD Spring ON) – Assemble
2 And 4 Wheel Drive Clutch (4WD Spring ON) – Pressure Testing
PTFE Piston Ring Seals
Fitting Procedure
P-TRONIC 6 x 4 Smoothshift
Technical Data
Unit Identification
Service Tools
Component Identification
External Components
Internal Components
Dismantling and Assembly
Transmission Charge Pump
Removal
Replacement
Dismantling
Transmission Control Valve
Removal
Replacement
Front and Rear P.T.O. Position Sensor
Removal
Replacement
Dismantling and Assembly
Front P.T.O.
Removal and Replacement
Rear P.T.O.
Removal
Replacement
Dismantle
Assemble
Front and Rear P.T.O. Clutches
Dismantling
Assembly
Mainshaft
Dismantle
Assemble
Rear Cover and Clutch Shafts
Removal
Replacement
Charge Pump Manifold
Removal
Replacement
Intermediate Cover and Clutch Shafts
Removal
Replacement
Centre Bearing Shaft
Removal and Replacement
Dismantling and Assembly
Transmission Brake
Dismantling and Assembly
Front and Rear P.T.O. Ratio Selector Shaft
Dismantling
Assembly
Ratio Clutches
Main Shaft Clutch (E) – Dismantle
Main Shaft Clutch (E) – Assemble
Ratio Clutches (A, B, C and D) – Dismantle and Assemble
Primary Shaft/Reverse Clutch Drum
Dismantle
Assemble
Wet Clutch Casing
Removal and Replacement
P.T.O. Idler Shaft
Removal and Replacement
Dismantling and Assembly
Shaft Setting
Idler Shaft
Dismantling
Assembly
P.T.O. Input Shaft
Dismantling and Assembly
Range Box – Dismantling
Range Box – Assembly
Four Wheel Drive Clutch
Mainshaft and Outputshaft
Range Box – Internal Pipework and Seals
Dismantling and Assembly
Range Box – Selector Rail Pistons
Dismantling and Assembly
Range Box – Mainshaft
Dismantling and Assembly
Range Box – Output Shaft
Dismantling and Assembly
Range Box – Four Wheel Drive Clutch
Dismantling and Assembly
Range Box – Position Sensors
Assembly
Wet Master Clutch – Removal
Wet Master Clutch – Replacement
Wet Master Clutch – Clutch Drum and Hub
Dismantling
Assembly
Wet Master Clutch – Clutch Plates and Plate Carrier
Dismantling
Assembly
Wet Master Clutch – Clutch Drum Carrier and PTO Input gear
Dismantling
Assembly

Section G – Transfer Gearboxes
Transfer Gearboxes
Bevel Gearbox
Technical Data
Unit Identification
Service Tools
Dismantle, Inspection and Assembly
Dismantle
Inspection
Assemble
TG300 Series Drop Box
Technical Data
Unit Identification
Sectional Drawing
Component Key
Service Tools
Dismantle, Inspection and Assembly
Dismantle
Inspection
Assemble
HG310 Series Drop Box
Technical Data
Unit Identification
Sectional Drawing
Component Key
Service Tools
Dismantle, Inspection and Assembly
Dismantle
Assemble
HG700 Series Drop Box
Technical Data
Unit Identification
Sectional Drawing
Component Key
Service Tools
Dismantle, Inspection and Assembly
Dismantle
Assemble
70 Series Drop Box
Technical Data
Unit Identification
Sectional Drawing
Component Key
Service Tools
Dismantle, Inspection and Assembly
Dismantle
Inspection
Assemble

 

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JCB Transmissions Service Manual – 9803/8610-14.pdf

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