JCB Drivetrain SS400 Series Tranmission With Transfer Gearbox – TG150 Service Manual - PDF DOWNLOAD

Service Manual JCB Drivetrain Systems Ltd Wrexham Industrial Estate WREXHAM United Kingdom LL13 9UF

General Information

1

Care & Safety

2

Routine Maintenance

3

Electrics

4

Transmission

5

NOTE All references in this manual to ‘Forward’ and ‘Reverse’ assume a front-mounted engine.

Tel: (01978) 661140 Fax: (01978) 661863

SS400 SERIES TRANSMISSION WITH TRANSFER GEARBOX - TG150 Publication No. 9803/9010 Issue 3

Section 1

General Information

1-1

Section 1 1-1

Unit Identification Syncro Shuttle Serial Plate The Syncro Shuttle serial number is stamped on a label which is mounted to the rear face of the unit.

1

When replacement parts are required, always ensure that the correct parts are obtained, e.g. in the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

2

When ordering replacement parts, quote the details on the serial plate shown.

3

It is essential that all gaskets and seals removed while dismantling, should be renewed on reassembly.

4

On reassembly care should be taken that all parts are correctly replaced since any component omitted or incorrectly assembled can lead to a complete failure.

5

Lubricants should comply with the recommended list as provided in this manual. It is important to adhere to the oil changing procedure.

6

It is advisable to lightly lubricate with a recommended lubricant, parts such as gears, shafts, thrust washers and oil seals during reassembly.

A317660

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Issue 3

Section 3

Routine Maintenance

Section 3

i

i

Contents

9803/9010

Page No.

Lubricants & Capacities

1-1

Transmission Oil Fill Procedure

1-1

JCB Drivetrain Dipstick Details

1-1

Lubricants - Health and Safety

1-2

Service Schedules

2-1

Syncro Shuttle Transmission - Check Level - Change Oil & Clean Strainer - Renew Filter

3-1 3-1 3-1

Issue 3

Section 3

Routine Maintenance

Section 3

1-1

1-1

Lubricants & Capacities ITEM

†SS400 Transmission

CAPACITY

litres *17.5

UK gal 3.8

Brake System

Grease Points * Electrical Connections

†

US gal 4.6

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Mobil ATF 210

ESP-M2C 33G

Mobil DTE 11M (Mineral Fluid) ISO VG15 Do not use conventional brake fluid as mineral fluid only must be used --

--

-

Mobil HP222

Mobil HP222

--

--

-

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

NB. Petroleum jelly must NOT be used on sealed-type connectors.

Capacities shown with an asterisk are approximate total system and dependent on vehicle circuit. Use the maximum and minimum marks on dipstick when filling.

Transmission Oil Fill Procedure Note: When installing a transmission in a machine, whether new or in service, it is extremely important to follow the correct oil fill procedure to prevent internal damage to the transmission.

1

With the engine stopped, fill the transmission with Mobil ATF210 oil to dipstick maximum mark (see Page 3 - 1).

2

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

3

Stop the engine, wait approximately one minute. Recheck the oil level and fill to dipstick level.

JCB Drivetrain Dipstick Details Tube size 1” O/D x 16 S.W.G. ERW 1 Locknut and seal required for securing and sealing dipstick/filler tube - Part No. 155/10600

X Y

Filler tube must sit fully home in transmission casing counterbore.

Note: Figures given below are for transmissions installed horizontally. Allowance may be needed if installed at an angle (Front to Rear). JCB Drivetrain should be consulted if transmission is to be inclined in vehicle chassis.

A B A234630

Transmission Figures Dimension A Dimension B

9803/9010

187 mm (max) 199 mm (min)

X Seal Ferrule Y Male nut fitting 11/2 in Hex. A/F

Issue 3*

Section 5 5-6

Transmission Gearbox

Section 5 5-6

Sump Oil Strainer - Procedure after Transmission Overhaul If the transmission is not thoroughly cleaned during overhaul, any particles below 200 micron (0.2 mm) can pass through the existing suction strainer and into the transmission pump before being caught in the pressure filter.

This can result in transmission pump failure and the transmission may have contamination related problems (scoring of bearings and clutch housing).

12

Refill the system with clean and correct specification oil (see JCB Drivetrain Service Manual - Lubricants and Capacities).

It is recommended that a special 75 micron (0.075 mm) service suction filter is temporarily fitted after a transmission overhaul to clean the system and prevent further damage.

The following procedure should be adopted:1

During the overhaul, the transmission should be cleaned as thoroughly as possible.

2

If a significant amount of particles and oil debris is present, then it is recommended that the oil cooler and pipework are cleaned or replaced.

3

Fill the transmission with clean, correct specification oil (see JCB Drivetrain Service Manual - Lubricants and Capacities).

Note: On remote transmissions the pump housing must be filled separately by priming the suction hose.

4

The transmission should be overfilled for initial start-up.

5

Disconnect the oil cooler feeder pipe at E and run the engine at idle.

6

Drain the excess oil into a suitable container which will prevent contaminated oil being pumped into the oil cooler or transmission. The transmission must be kept full at all times.

7

Reconnect the oil cooler at E. Run the machine to working temperature and carry out functional tests.

8

Remove the connection or plug from the suction strainer and drain the system.

Note: Drain through the strainer, not the drain plug and DO NOT re-use this oil as it will be contaminated.

9

Remove and clean the service suction strainer with its magnet. Retain for future use.

10

Fit the production suction strainer, tightening bolts F to 7 - 10 Nm (5.2 - 7.3 lbf ft).

Note: On remote transmissions tighten pipe adapter H to 20 Nm (14.75 lbf ft).

11

Fit a new pressure filter C.

Note: The pressure filter should be changed again after 100 hours running.

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Issue 3

Section 5

Transmission Gearbox

7-6

Section 5 7-6

Assembly (Cont'd) 28

Temporarily refit taper plug 67.

29

Remove short extension from adaptor.

30

Fit the rear output yoke 15, washer 14 and stake nut 13. Torque tighten to 350 Nm (258.2 lbf ft).

31

Fit the output yoke adaptor J and secure with bolts K. Torque tighten to 22 Nm (16.2 lbf ft). Screw the adaptor C into the yoke adaptor extension L until tight.

32

Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E in the appropriate position on the base plate A and secure with bolts F. Tighten the bolts.

33

Fit a magnetic base DTI G onto the base plate with the pin resting on the top of the adaptor.

34

Measure the output shaft end float and determine shim thickness by repeating steps 19 and 20. Refer to view Y.

39

Clean the mounting face of the flywheel housing. Mount the DTI on the face with the probe resting on the end of the reverser unit shaft. Firmly press the reverser unit shaft in to take up any shaft end float. Zero the DTI. Refer to view Z.

40

Screw a threaded bolt or rod into the threads exposed when oil inlet adaptor 65 was removed, until it touches the end of the reverser unit shaft.

S204050 S204010

35

36

37

38

41

Screw bolt or rod in further (approx. 10 Nm; 7.4 lbf ft) whilst turning output shaft. Stop when increasing resistance is felt. DO NOT overtighten. Take the DTI reading.

42

Calculate the required shim thickness as detailed in step 20.

Remove the lever unit, adaptor, base plate and output yoke adaptor.

43

Remove bolt or rod and the DTI. Temporarily refit oil inlet adaptor 65 and sealing washer 66.

Remove the rear stake nut 13, washer 14 and output yoke 15.

44

Turn the gearbox into the vertical position, with the rear casing upwards.

Remove oil inlet adaptor 65 and sealing washer 66 from the rear casing.

45

Screw a lifting eye into a brake housing bolt hole. Using a suitable hoist, lift the rear casing 37 away from the front casing 38. Prise bars may be used at the points provided to assist in 'cracking' the joint. Turn the rear casing over.

Turn the gearbox into the horizontal position.

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Issue 1