JCB SD 55/ST Axle Service Manual - PDF DOWNLOAD

Foreword The Operator's Manual

SERVICE MANUAL

You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it.

Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.

Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.

SD55 Axle Contents 01 - Machine 27 - Driveline 30 - Hydraulic System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales

EN - 9823/0100 - ISSUE 1 - 06/2018

This manual contains original instructions, verified by the manufacturer (or their authorized representative).

Copyright 2017 Š JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

www.jcb.com

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Spine Cards

SERVICE MANUAL

SERVICE MANUAL

SD55 Axle

SD55 Axle

EN 9823/0100

EN 9823/0100

SERVICE MANUAL

SERVICE MANUAL

SD55 Axle

SD55 Axle

EN 9823/0100

EN 9823/0100

Volume 1

Volume 3

Volume 2

Volume 4

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01 - Machine Contents

Page No.

01-03 Safety 01-03-03 Safety - Yours and Others ............................................................................................... 01-3 01-03-06 Safety Warnings ............................................................................................................... 01-4 01-03-09 General Safety ................................................................................................................. 01-5 01-03-12 Maintenance Safety ......................................................................................................... 01-6 01-03-18 Operating Safety .............................................................................................................. 01-8 01-06 About this Manual 01-06-00 General ........................................................................................................................... 01-13

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03 - Safety

03 - Safety Contents 01-03-03 01-03-06 01-03-09 01-03-12 01-03-18

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Page No. Safety - Yours and Others ...............................................................................................

Safety Warnings ...............................................................................................................

General Safety .................................................................................................................

Maintenance Safety .........................................................................................................

Operating Safety ..............................................................................................................

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03 - Safety

03 - Safety - Yours and Others

03 - Safety - Yours and Others Health and Safety All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.

In this manual and on the machine you will find warning messages, you must read and understand them. They inform you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB dealer to explain them.

Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking of what hazards there might be and how to avoid them.

Do not work with the machine until you are sure that you can control it.

Do not start any work until you are sure that you and those around you will be safe.

If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume anything.

Remember: • • •

Be careful Be alert Be safe.

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03 - Safety

06 - Safety Warnings

06 - Safety Warnings Health and Safety In this manual there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious injury.

The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or serious injury.

The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.

The safety alert system symbol (shown) also helps to identify important safety messages in this manual.

When you see this symbol your safety is involved, carefully read the message that follows.

Figure 1. The safety alert system symbol

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09 - General Safety

Lifting Equipment

Health and Safety Training To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's manual instructs you on the machine, its controls and its safe operation; it is not a training manual. Ensure that you receive the correct training before operating any machinery. Failing to do so will result in incorrect operation of the machine and you will be putting yourself and others at risk. In some markets, and for work on certain jobsites, you may be required to have been trained and assessed in accordance with an operator competence scheme.

Make sure that you and your machine comply with relevant local laws and jobsite requirements – it is your responsibility.

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

You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.

Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped).

Make sure that no-one goes near the machine while you install or remove the mechanical device.

Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

Lightning

Clothing

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

You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery.

This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in any way which could affect or invalidate its compliance. For advice consult your JCB dealer.

Alcohol and Drugs

Machine Modifications

It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness.

Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with.

Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.

Switch off and do not use your mobile phone when refuelling the machine.

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12 - Maintenance Safety

Hydraulic Pressure

Health and Safety Raised Machine Never position yourself or any part of your body under a raised machine which is not correctly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

Air Conditioning Maintenance The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person. You can be severely frostbitten or injured by escaping refrigerant.

Compressed Air Compressed air is dangerous. Wear personal protective equipment. Never point a compressed air jet at yourself or others.

Springs Always wear personal protective equipment when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out.

Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper drift to remove and install metal pins.

Always wear personal protective equipment.

Communications Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the others are doing.

Before starting the engine make sure the others are clear of the danger areas. Examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken.

Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

Hydraulic fluid at system pressure can injure you.

Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.

'O' rings, Seals and Gaskets Badly installed, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.

Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements.

If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (ECUs), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components.

Parts of the machine are made from cast iron, welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.

Always connect the welder earth (ground) cable to the same component that is being welded to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable a distance from the part being welded no more than 0.6 m.

Counterweights Your machine may be installed with counterweights.

They are extremely heavy. Do not attempt to remove them.

Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be discharged by a JCB dealer, as the sudden release of the hydraulic fluid or gas may cause serious injury or death.

Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

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12 - Maintenance Safety

Working Under the Machine Make the machine safe before getting beneath it.

Make sure that any attachments on the machine are correctly attached. Engage the park brake, remove the ignition key, disconnect the battery. If the machine has wheels use blocks to prevent unintentional movement.

Lifting the Machine Under no circumstances must the engine be run with the transmission in gear and only one driving wheel jacked clear of the ground, since the wheel on the ground will move the machine.

Chemicals Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton®, FluorelTM and Technoflon®. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. This acid can severely burn. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300 °C ( 571.6 °F) require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions.

Do not touch component or surrounding area.

Used fluoroelastomeric components subjected to temperatures greater than 300 °C ( 571.6 °F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains. Thoroughly wash contaminated area with detergent and water.

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations. Do not burn fluoroelastiometric materials.

Hydraulic Hoses Never re-use hydraulic hose end crimps or use reusable hose end crimps.

Personal Protective Equipment Use the appropriate personal protective equipment before performing maintenance on the machine, otherwise you could be injured.

Working at Height Use appropriate access equipment such as ladders or a working platform if it is necessary to work at height to perform maintenance tasks on the machine.

If you do not use suitable access equipment there is a risk of falling, resulting in personal injury or death.

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exhaust extractor. If you begin to feel drowsy, stop the machine at once and get into fresh air.

Health and Safety

Worksites

Training Make sure that you have had adequate training and that you are confident in your ability to operate the machine safely before you use it. Practice using the machine and its attachments until you are completely familiar with the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life, or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your colleagues what you will be doing and where you will be working. On a busy site, use a signalman. Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will be glad to advise you.

Fuel Fuel is flammable, keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.

Machine Condition A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine.

Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous.

Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications or additional equipment.

Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

Exhaust Gases Machine exhaust gases can harm and possibly kill you or bystanders if they are inhaled. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, install an 01 - 8

Worksites can be hazardous. Examine the site before working on it. You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it. Check for potholes and hidden debris, logs, ironwork etc. Any of these could cause you to lose control of your machine.

Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes.

Make sure that you have enough clearance beneath overhead cables and structures.

Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Worksites can be noisy, do not rely on spoken commands.

Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Manual to park the machine correctly.

Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse.

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

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

Hazardous Atmospheres This machine is designed for use in normal out door atmospheric conditions. It must not be used in an enclosed area without adequate ventilation.

Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB dealer.

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Regulations Obey all laws, worksite and local regulations which affect you and your machine.

clearly. Modification of the machine's configuration by the user (e.g. the fitting of large and nonapproved attachments) may result in a restriction of the machine visibility.

Electrical Power Cables

Hands and Feet

You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines. Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site. There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.

Keep your hands and feet inside the machine. When using the machine, keep your hands and feet clear of moving parts. Keep your hands and feet within the operator compartment while the vehicle is in motion.

Working Platform

Passengers

Using the machine as a working platform is hazardous. You can fall off and be killed or injured.

Never use the machine as a working platform unless with approved man-basket or man-crate (if applicable).

Passengers in or on the machine can cause accidents. Do not carry passengers.

Machine Safety Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Examine and repair before resuming work.

Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.

Travelling at High Speeds Travelling at high speeds can cause accidents.

Always travel at a safe speed to suit working conditions.

Hillsides

Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated.

Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible.

Roll Over Protection If the machine starts to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.

Confined Areas Pay extra attention to proximity hazards when operating in confined areas. Proximity hazards include buildings, traffic and bystanders.

Operating the machine on hillsides can be dangerous if the correct precautions are not taken.

Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. When applicable, keep all attachments low to the ground.

Safe Working Loads

Visibility

Lightning

Accidents can be caused by working in poor visibility.

Use your lights to improve visibility. Keep the road lights, windows, mirrors and cameras clean (when fitted). Do not operate the machine if you cannot see

If you are inside the machine during a lightning storm stay in the machine until the storm has passed. If you are outside of the machine during a lightning storm stay away from the machine until the storm

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Overloading the machine can damage it and make it unstable. Study the specifications in the Operator's Manual before using the machine.

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has passed. Do not attempt to mount or enter the machine. If the machine is struck by lightning do not use the machine until it has been checked for damage and malfunction by trained personnel.

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06 - About this Manual

06 - About this Manual Contents

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01-06-00 General ........................................................................................................................... 01-13

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06 - About this Manual 00 - General

00 - General Introduction This manual is built up in a modular way to include procedures for disassembling, inspection and assembly of JCB axles and gearboxes. It should be noted that procedures given in this manual are for transmission assemblies only. Service procedures specific to machine transmission installations are given in the relevant machine service manual.

When applicable, procedures in this manual are referred to in the JCB machine service manual. To check the cross reference see the transmission Technical Data pages in the machine service manual. There are many transmission variants, ensure that you are referencing the correct procedures for the applicable transmission assembly.

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27 - Driveline Contents

Page No.

Acronyms Glossary .................................................................................................................................... 27-2 27-20 Axle(s) 27-20-00 General ............................................................................................................................. 27-3 27-22 Drivehead 27-22-00 General ........................................................................................................................... 27-21 27-22-06 Crownwheel .................................................................................................................... 27-41 27-22-09 Pinion Gear .................................................................................................................... 27-43 27-24 Differential 27-24-00 General ........................................................................................................................... 27-47 27-27 Hub 27-27-00 General ........................................................................................................................... 27-67 27-47 Propshaft 27-47-00 General ........................................................................................................................... 27-83 27-51 Driveshaft 27-51-00 General ........................................................................................................................... 27-89 27-51-15 Shaft Hub Side ............................................................................................................... 27-93

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Acronyms Glossary DTI

Dial Test Indicator

LSD

Limited Slip Differential

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27-20-00 General ............................................................................................................................. 27-3

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00 - General

Introduction

Introduction ...................................................... 27-3 Technical Data ................................................. 27-4 Component Identification ................................. 27-5 Drain and Fill ................................................... 27-7 Check (Level) ................................................ 27-10 Lubricate ........................................................ 27-11 Remove and Install ....................................... 27-12 Disassemble and Assemble .......................... 27-17

Axles are an integral component of a wheeled vehicle. The axle transmits a driving torque to the wheel, as well as maintaining the position of the wheels relative to each other and to the vehicle body.

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Technical Data Table 1. SD 55/NT Axle Type Designation Types of Brakes Installation Number of steer cylinders Weight (dry, with no steer cylinders and without wheels) Ratios Overall Crownwheel and Pinion Number of Teeth Crownwheel Pinion Hub Reduction

JCB Drivetrain spiral bevel input with epicyclic hub reduction.

SD 55/NT Oil immersed multi-plate disc located in hubs.

Centre pivot or rigid pad mount 1 Pin: 367 kg approx.

Option1 10.46:1 1.94:1

Option2 12.24:1 2.26:1

Pad: 365 kg approx.

Option3 16.2:1 3.0:1

31 34 33 16 15 11 5.4:1 6.0:1 (SD40 and SD70 hubs only) 1480 half yoke 0° 0°

Option4 18.6:1 3.44:1

Option5 19.2:1 3.55:1

Option6 20.93:1 3.875:1

Option7 23.625:1 4.375

31 9

32 9

31 8

35 8

Input type Toe-in Caster angle Camber an- 1° gle Kingpin in- 0° clination

Table 2. Service Brake - 2 Plate, Positive Retraction (Power Braked Machines) Type Actuation Location Friction plates Outside diameter Inside diameter Nominal facing area/ plate

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Oil-immersed multi-plate disc Hydraulic Outboard - Axle hub 2 per brake (i.e. 4 per axle) 220 mm 180 mm 12616 mm²

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Component Identification Unit Identification

Figure 2.

The axle serial number is stamped on the unit identification plate as shown. When you make an order for parts replacement, always quote the details on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

A

A Identification plate

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20 - Axle(s) 00 - General

Main Component Identification Figure 3.

6 7

8

10

1 2

3 4

5

11

Table 3.

Item 1 2 3 4 27 - 6

Description Counter plates Friction plates Brake carrier Driveshaft

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Description Stub axle arm Brake piston Reaction pin Brake piston housing Drive head housing Differential unit 27 - 6

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20 - Axle(s) 00 - General

Drain and Fill Notice: The oil level must be checked with the machine level, otherwise a false indication of the amount of oil will be given.

axle for your machine. Refer to Figure 4. and Refer to Figure 5.

1.2. Then make sure you identify the correct plug for your machine.

Notice: It is not recommended that the machine be driven with the axle partially filled with oil.

1.3. Then use the related torque information for the drain plug. Refer to Table 4. and Refer to Table 5.

Remove 1. Make the machine safe. Refer to (PIL 01-03).

2. Get access to the axle drain plug.

2. Remove the hexagonal fill/level plug with its sealing washer (if installed) or the tapered plug.

3. Clean the area around the drain plug.

3. Fill with the specified oil until oil is level with the bottom of the hole. Refer to (PIL 75-00).

4. Drain the oil.

4. Clean the fill/level plug.

4.1. Place a container of suitable size beneath drain plug to catch the oil.

5. Install the fill/level plug with its sealing washer (if installed) or the tapered plug.

4.2. Remove the hexagonal drain plug and its washer (if installed) or the tapered plug.

Allow oil to drain out. Wipe it clean (metallic particles should be carefully removed).

6. Tighten the fill/level plug to the correct torque value.

6.1. To Make sure you use the correct torque tightening information, identify the correct axle for your machine. Refer to Figure 4. and Refer to Figure 5.

Install 1. Install the drain plug (and sealing washer- if installed), tighten to the correct torque.

6.2. Then make sure you identify the correct plug for your machine.

1.1. To Make sure you use the correct torque tightening information, identify the correct

6.3. Then use the related torque information for the fill/level plug. Refer to Table 4. and Refer to Table 5.

Figure 4. JCB Axle (Inboard Brakes)

C A B C A Axle fill/level plug C Hub drain plug

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B Axle drain plug

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Figure 5. JCB Axle (Braked Hubs) F

F

D E

D Axle fill/level plug F Hub drain plug

E Axle drain plug

Figure 6. Hexagonal Plug and Sealing Washer (Prior to January 2011)

Figure 7. Taper Plug (January 2011 Onwards)

Table 4. JCB Axles With Inboard Brakes Function of Plug Installed Axle drain plug with hexagonal head and bonded washer Axle drain plug with tapered plug Axle fill plug with hexagonal head and bonded washer Axle fill plug with tapered plug

Description Hex head plug and washer (3/4 in BSP) Taper plug (3/4 in BSP) Hex head plug and washer (3/4 in BSP) Taper plug (3/4 in BSP)

Torque (Nm) 90 80 90 80

Table 5. Axles With Braked Hubs Function of Plug Installed Axle drain plug with hexagonal head and bonded washer Axle drain plug with tapered plug

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Description Hex head plug and washer (3/4 in BSP) Taper plug (3/4 in BSP)

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Torque (Nm) 90 80

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Function of Plug Installed Axle fill plug with hexagonal head and bonded washer Axle fill plug with tapered plug

Description Hex head plug and washer (3/4 in BSP) Taper plug (3/4 in BSP)

Torque (Nm) 90 80

Also refer to hub, general, drain and refill, (PIL 27-00).

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Check (Level) (For: 55 Series (1 Piece Axle)) Notice: The oil level must be checked with the machine level, otherwise a false indication of the amount of oil will be given.

1. Make the machine safe.

2. Clean the area around the fill/level plug.

3. Remove the plug and the sealing washer.

4. Oil should be level with the bottom of the hole.

5. Add the recommended oil if necessary.

6. Clean and install the plug and the washer.

Figure 8.

A

B A Fill/level plug B Drain plug

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Lubricate When greasing, raise the wheels and swing them from lock to lock. This will ensure the full penetration.

Figure 9.

3

1

5

2

4

6

8 9

7

1 3 5 7 9

Grease point Grease point Grease point Grease point Grease point

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2 4 6 8 10

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10

Grease point Grease point Grease point Grease point Grease point

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20 - Axle(s) 00 - General

Remove and Install Special Tools Description Splined Bolt Socket

Part No. 892/00822

4. Disconnect the hydraulic pipes from the steer cylinder, blank off all exposed connections.

Qty. 1

5. Loosen the road wheel retaining nuts.

WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end.

Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

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

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

7. Remove the road wheels.

8. Position a jack underneath the balance point.

8.1. Important: The drive head assembly is offset, so the balance point of the axle is not at the centre of the axle. Attach a ‘cradle’ to the jack that will partially support the axle.

9. Remove the nut and pivot pin retaining bolt.

10. Use a suitable puller to remove the pivot pin.

11. Lower the jack so that the axle is clear of the mounting yoke and remove the axle.

Remove and Install (PIN Mounted) Remove 1. Make the machine safe. Refer to (PIL 01-03).

2. Use the special tool to remove the bolt to disconnect the propshaft from the axle.

Special Tool: Splined Bolt Socket (Qty.: 1)

Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps.

2. Apply Loctite 242 to the threads of bolts.

3. Disconnect the brake pipes from the axle swivel hubs, blank off the exposed connections.

27 - 12

6. Prop the machine on each side.

3. Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

9823/0100-1

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27 - Driveline

20 - Axle(s) 00 - General

Figure 10.

E

D

A F

C

B

A Bolt C Tripod jack E Bolt

B Nut D Nut F Pivot pin

Remove and Install (PAD Mounted)

2. Use the special tool to remove the bolt to disconnect the propshaft from the axle.

Remove

Special Tool: Splined Bolt Socket (Qty.: 1)

1. Make the machine safe. Refer to (PIL 01-03).

27 - 13

3. Disconnect the brake pipes from the axle swivel hubs, blank off the exposed connections.

9823/0100-1

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27 - Driveline

20 - Axle(s) 00 - General

4. Disconnect the hydraulic pipes from the steer cylinder, blank off all exposed connections.

9. Remove the nut, bolts and washers.

5. Loosen the road wheel retaining nuts.

10. Lower the jack so that the axle is clear of the mounting yoke and remove the axle.

6. Prop the machine on each side.

Install

7. Remove the road wheels.

1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps.

8. Position a jack underneath the balance point.

8.1. Important: The drive head assembly is offset, so the balance point of the axle is not at the centre of the axle. Attach a ‘cradle’ to the jack that will partially support the axle.

27 - 14

2. Apply Loctite 242 to the threads of bolts.

3. Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.

9823/0100-1

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20 - Axle(s) 00 - General

Figure 11.

A

C

B

E

F D

A Bolt C Tripod jack 27 - 15

B Nut D Nut 9823/0100-1

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27 - Driveline

20 - Axle(s) 00 - General

E Bolt

F Washer Table 6. Torque Values

Item A B D

27 - 16

Nm 44 680 476

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20 - Axle(s) 00 - General

Disassemble and Assemble Consumables Description JCB Gear Oil HP JCB Multi-Gasket JCB Threadlocker and Sealer (Medium Strength)

Part No. 4000/0505 4000/0503 4102/1212 4101/0250 4101/0251

Size 20 L 200 L 0.05 L 0.01 L 0.05 L

Disassembly

6. Remove the brake pack.

7. Remove the circlip.

8. The wear limit of friction plates is to the depth of the cross hatching.

9. Check all plates for flatness and damage.

10. Scoring of the counter plates to a certain limit is permissible.

11. Install a new brake pack, if it is damaged.

Note: Make sure that only one side at a time is disassembled to prevent damage to the bearings and preserve the crown wheel and the backlash settings.

The axle must be removed from the machine when you disassemble the rear axle brakes.

Before you disassemble the rear axle brakes, it is mandatory to mark the components for alignment and to identify the right hand and left hand side, to make suer that it is correctly assembled at the time of assembly.

1. Use a heavy duty (6 point) socket to remove the bolt.

12. Make sure that you do not install new plates individually.

13. Remove all the three reaction pins and check them for damage.

14. Before you remove the brake housing and the piston assembly make sure that you support the differential with the driveshaft or any other suitable support.

15. Mark the brake piston housing and the drivehead.

16. Remove the capscrews.

2. Carefully remove the stub axle arm from the drivehead.

17. Remove the brake housing and the piston assembly.

3. If necessary, tap the case with a soft faced hammer and remove all traces of the old sealant from the mating faces.

18. Remove the brake piston from the brake housing.

4. The brake pack consist of three friction plates and four counter plates. There are two counter plates, one at each end of the brake pack, which are not attached to the plate carrier.

19. Remove and discard the seal 1 and seal 2.

20. Check the housing bore for damage and scoring.

21. Nicks or cuts in the seals may be the reason for loss of brake fluid.

5. If it is necessary to install the plates again then make a note of their position and correct the orientation.

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20 - Axle(s) 00 - General

Figure 12.

K

J

L N

P

Q

M

B

G

F

B

E

C

D

A H

A C E G J L N Q

Bolt Plate carrier Reaction pin Oil flow holes Brake piston housing Capscrew Seal 1 Seal 2

27 - 18

B D F H K M P

Counter plate Circlip Cross hatching Suitable support for differential Drivehead housing Nut Brake piston

9823/0100-1

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20 - Axle(s) 00 - General

Assembly

Consumable: JCB Threadlocker and Sealer (Medium Strength)

1. Remove all traces of the old sealant from the mating faces of the drive head and the brake piston housing.

21. Put the stub axle on to the drivehead. Make sure that they are aligned correctly.

2. Install a new seal 1 and seal 2. Make sure they seat squarely in their grooves.

22. Install the bolt and tighten the bolt to the correct torque value.

3. Carefully push the brake piston into the brake piston housing.

Table 7. Torque Values

4. Apply JCB Multigasket to the drivehead mating face and then install the brake piston housing assembly.

Item A L

Description Bolt Capscrew

Nm 98 46

Consumable: JCB Multi-Gasket 5. Make sure that the brake piston housing is aligned correctly.

6. Install the capscrews, tighten the screws to the correct torque value.

7. Remove the differential support.

8. Soak the new friction plates in JCB Special Gear Oil before assembly.

Consumable: JCB Gear Oil HP 9. Assemble the three friction plates and four counter plates onto the brake carrier.

10. If the original brake pack is reused then place the plates to their original position.

11. Install the circlip.

12. Make sure that brake pack oil flow holes must be aligned with each other when being installed to the brake pack carrier.

13. Put the three reaction pins into their grooves and lubricate them.

14. Push the pins fully into their location holes in the housing.

15. Install the three reaction pins into their grooves and secure them. Press the pins fully into location holes in the housing.

16. Install one counter plate into the housing, lubricate it and then the other counter plate.

17. If the old counter plates are re installed then put them into their original position.

18. Fully press the brake pack in the housing.

19. Apply JCB multigasket to the mating surface of the drivehead.

Consumable: JCB Multi-Gasket 20. Apply sealant to the bolt thread.

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22 - Drivehead

22 - Drivehead Contents

Page No.

27-22-00 General ........................................................................................................................... 27-21 27-22-06 Crownwheel .................................................................................................................... 27-41 27-22-09 Pinion Gear .................................................................................................................... 27-43

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22 - Drivehead 00 - General

00 - General

Introduction

Introduction .................................................... 27-21 Component Identification ............................... 27-22 Disassemble and Assemble .......................... 27-28

The axle drivehead transmits drive from the input coupling yoke to the driveshafts through the differential unit.

27 - 21

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22 - Drivehead 00 - General

Component Identification Figure 13.

For: 55 Series (3 Piece Axle) ..... Page 27-22 For: 55 Series (1 Piece Axle) ..... Page 27-24

(For: 55 Series (3 Piece Axle)) Unit Identification The axle serial number is stamped on the unit identification plate. When ordering replacement parts, always quote the details on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

27 - 22

A

A Identification plate

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22 - Drivehead 00 - General

Location Drawing (448/00063) Figure 14.

1

15

11

10

16

14 13

12

2

3 4

5

6 7 8 Table 8.

Item 1 2 3 4 5 6 7 8 27 - 23

Description Drive case Bearing (taper roller) Shim Spacer Bearing (taper roller) Pinion seal Coupling yoke Stake nut

Item 10 11 12 13 14 15 16

9823/0100-1

Description Bolt Verbus-ripp Crownwheel and pinion assembly Bearing (taper roller) Side nut Brake piston Differential assembly Brake piston housing

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22 - Drivehead 00 - General

(For: 55 Series (1 Piece Axle))

Figure 16.

Unit Identification The axle serial number is stamped on the unit identification plate as shown. When you make an order for parts replacement, always give the details mentioned on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

Figure 15.

A Identification plate A

A Identification plate

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22 - Drivehead 00 - General

Main Component Identification Figure 17.

4

5

1

2

3

6

Table 9.

Item 1 2 3 4

27 - 25

Description Coupling yoke Driveshaft Side nut Pinion

Item 5 6 7 8

9823/0100-1

7

8

Description Bevel gears Side nut locking pin Differential housing Crownwheel

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22 - Drivehead 00 - General

Location Drawing (448/00040) Figure 18.

10

15

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

Table 10.

Item 1 2 3 27 - 26

Description Drivehead carrier Bearing (taper roller) Shim

Item 4 5 6 7 8 9823/0100-1

Description Spacer Bearing (taper roller) Pinion seal Coupling yoke Stake nut 27 - 26

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22 - Drivehead 00 - General

Item 10 11 12 13 14 15

27 - 27

Description Bolt-Verbus Ripp Crown wheel and pinion assembly Bearing (taper roller) Side nut Side nut locking pin Differential assembly

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22 - Drivehead 00 - General

Disassemble and Assemble For: 55 Series (3 Piece Axle) ..... Page 27-28 For: 55 Series (1 Piece Axle) ..... Page 27-35

(For: 55 Series (3 Piece Axle)) Special Tools Description Drive Coupling Spanner Setting Tool Kit Spacer Kit Torque Wrench (10-100Nm) Support Bracket

2. Mark the brake piston housing and the drivehead for their correct assembly with respect to each other. Refer to Figure 19.

3. Remove the brake piston housing. Refer to Figure 19.

Part No. 892/00812

Qty. 1

892/00918 921/53300 993/70111

1 1 1

997/11000

1

4. Remove the differential side nut locking pin to allow for readjustment on assembly. Refer to Figure 20.

Figure 20.

C

Disassembly When the drivehead is installed on the machine it cannot be disassembled. It is recommended that you remove the complete axle.

The crownwheel and pinion are matched and should be replaced as a pair, if either of them are damaged or excessively worn.

The two differential case halves are also matched as are the differential side gears and planet gears, do not use unmatched halves or gears.

1. Place the drivehead with the crownwheel at the top and then remove the capscrews. Refer to Figure 19.

Figure 19.

B

C Side nut locking pin 5. Remove the other brake piston housing if it is damaged, but its locking pin must be removed to allow the side load adjustment on assembly.

Refer to Figure 20.

6. Lift off the crownwheel/ differential assembly.

Refer to Figure 21.

A

A Capscrew B Brake piston housing

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22 - Drivehead 00 - General

Figure 22.

Figure 21.

H

D

J E

G F

E F G H J

D Crownwheel/ differential assembly 7. If it is necessary to remove the brake piston housings then mark the crownwheel end of the drivehead case to make sure that they are correctly assembled at the time of assembly.

Refer to Figure 21.

8. Use the spanner to lock the drive yoke and then remove the stake nut and the yoke. Refer to Figure 22.

Special Tool: Drive Coupling Spanner (Qty.: 1) 9. Use a soft faced hammer to hit the pinion end shaft until the pinion is free from its front bearing and then remove the pinion. Refer to Figure 22.

Pinion Pinion seal Outer bearing cone Inner bearing cup Shim

11. If necessary, drive out the pinion inner bearing cup and shims. Refer to Figure 22.

12. Discard the shims. Refer to Figure 22.

13. Do the step 11 to remove the outer bearing cup.

Refer to Figure 22.

14. There are no shims for the outer bearing cup.

Refer to Figure 22.

15. Remove the pinion spacer. Refer to Figure 23.

Figure 23.

10. Remove the pinion seal and the outer bearing cone. Refer to Figure 22.

K

L

K Inner bearing cone L Pinion spacer 16. Remove the inner bearing cone. Refer to Figure 23.

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22 - Drivehead 00 - General

17. Disassembly of the differential unit. Refer to Figure 24.

17.1. Remove the bolts.

6. Put the top half of the differential housing on to the differential and make sure that you have aligned it correctly. Refer to Figure 25.

Figure 25.

17.2. Lift off the top half housing.

Figure 24.

M M

R R

N S

N S

P

Q

P

Q

M N P Q R S

M N P Q R S

Bolt Top half housing Spherical washer 1 Spherical washer 2 Differential bearing cone Differential gear

Bolt Top half housing Spherical washer 1 Spherical washer 2 Differential bearing cone Differential gear

7. Apply Loctite 242 to the threads of the bolts and then install them. Refer to Figure 25.

17.3. Remove the differential gears, the spherical washer 1 and spherical washer 2.

8. Tighten the bolt to the correct torque value. Refer to Figure 25.

17.4. Remove the differential bearing cones.

9. Check the gears for free rotation. Refer to Figure 25.

Assembly 1. If necessary, install a new crownwheel to the differential case half.

10. Install the new inner bearing cone on to the pinion. Refer to Figure 26.

2. Install the crownwheel retaining bolt.

3. Tighten the bolt to the specified torque value.

Torque: 94 N¡m 4. Assemble the differential gear and the spherical washer 1 and spherical washer 2 into the bottom half of the differential housing. Refer to Figure 25.

5. Install the differential bearing cones. Refer to Figure 25.

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22 - Drivehead 00 - General

Figure 27.

Figure 26.

K

H

L

J E

G F K Inner bearing cone L Pinion spacer 11. Install the largest available solid spacer (14.20mm) from the solid spacer setting kit. Refer to Figure 26.

E F G H J

Special Tool: Spacer Kit (Qty.: 1) 12. Find the correct thickness for the shims. Refer to Front Drivehead, Pinion Gear- Calibrate. Refer to Figure 26.

Refer to: PIL 27-22-09.

13. Install the shims behind the pinion inner bearing cup. Refer to Figure 27.

14. Use a puller tool to make sure that the inner bearing cup is installed in square. Do not use a hammer. Refer to Figure 27.

15. Install the outer bearing cup. Refer to Figure 27.

16. Put the pinion into its bore. Refer to Figure 27.

Pinion Pinion seal Outer bearing cone Inner bearing cup Shim

17. Before you put the pinion into the bore, make sure that it is matched with the crownwheel.

Refer to Figure 27.

18. The code numbers etched on the pinion end face and the crownwheel perimeter should be the same. Refer to Figure 27.

19. Install the pinion outer bearing cone. Refer to Figure 27.

20. Do not install the oil seal at this stage. Refer to Figure 27.

21. Install the special tool sleeve and the special pinion shaft adapter. Refer to Figure 28.

Special Tool: Setting Tool Kit (Qty.: 1) 22. Tighten the adaptor to the correct torque value.

Refer to Figure 28.

23. Make sure that the pinion is free to rotate and there is end float. Refer to Figure 28.

24. End float will prevent the bearing from damage.

Refer to Figure 28.

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22 - Drivehead 00 - General

Figure 29.

Figure 28.

Z

T

Y

U

X

V

W T U V W

Pinion shaft adaptor Special tool sleeve Special bracket Bolt (M10x30)

1

X Support pillar Y DTI Z Torque wrench

25. If the pinion is not free to rotate or there is no end float at this stage check the bearing is installed correctly. Refer to Figure 28.

33. Set the torque wrench to the specified value and measure the end float while you rotate the shaft.

Refer to Figure 29.

Torque: 35 N¡m Special Tool: Torque Wrench (10-100Nm) (Qty.: 1)

26. Make sure that the correct size spacer is installed. Refer to Figure 28.

27. Use two bolts (M10x30) to install the special bracket to the drivehead housing. Refer to Figure 28.

34. Correct size solid spacer selection. Refer to Figure 29. Refer to Table 11.

34.1. To select the correct size spacer, subtract the end float obtained at step 33 from the solid spacer size (14.20 mm).

Special Tool: Support Bracket (Qty.: 1) 28. Install the special tool support pillar to the bracket so that the fork end engages in adaptor. Refer to Figure 28.

34.2. Also subtract 0.04 mm to allow for theoretical bearing tolerance and pre load.

34.3. The result is the size of spacer to be installed from the solid spacer kit.

29. Make sure that the fork is centrally located on the adaptor. Refer to Figure 28.

34.4. If there is no spacer of this size, fit the next nearest size spacer from the spacer kit.

30. If necessary, align the bracket again. Refer to Figure 28.

31. Install a DTI (Dial Test Indicator). Refer to Figure 29.

32. Make sure that the DTI is installed on the drivehead not on the bracket. Refer to Figure 29.

Special Tool: Spacer Kit (Qty.: 1) 35. Remove the sleeve and the temporary spacer.

Refer to Figure 28.

36. When you remove the temporary spacer make sure that the outer bearing is not damaged. Refer to Figure 28.

37. Install the correct size spacer from the spacer kit.

Refer to Figure 28.

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22 - Drivehead 00 - General

38. Install the sleeve. Refer to Figure 28.

39. Tighten the adaptor to the specified value, to protect against bearing damage while spacer selection is verified and make sure that the pinion is free to rotate. Refer to Figure 28.

Torque: 50 N·m 40. Check there is no end float and pinion is free to turn smoothly by hand. Refer to Figure 28.

41. Remove the adaptor and install the stake nut.

Refer to Figure 28.

42. Check that rolling torque is less than 2.0 Nm. If the rolling torque exceeds 2.0 Nm, check that the shaft is assembled correctly. Refer to Figure 28.

43. If the pinion is not free to rotate then check the correct size spacer is installed or not. Refer to Figure 28.

49. Gradually tighten the stake nut to the minimum specified torque value, occasionally rotate the coupling yoke. Refer to Figure 30.

Torque: 250 N·m 50. If the correct size spacer is selected, the rolling torque should be within the specified torque value including the seal drag. Refer to Figure 30.

Torque: 2.3 –3.4 N·m 51. When the torque value is correct, use a squareended staking tool to stake the nut to the pinion shaft. Refer to Figure 30.

52. The stake nut tightening torque value can be increased to a maximum of 300 Nm if the pinion rolling torque does not exceed the maximum of 3.4 Nm. Refer to Figure 30.

Figure 31.

44. If rolling torque measured at step 42 is too high then install the next larger size spacer. If the rolling torque is too low then install the next smallest size spacer. Refer to Figure 28.

45. If a correct spacer is not available from the range, check that drivehead is assembled correctly.

Refer to Figure 28.

46. Remove the stake nut and the sleeve. Refer to Figure 28.

47. Lubricate the seal lips and then install the new oil seal. Refer to Figure 30.

Figure 30.

AA

53. If the brake piston housing is removed then install one at the opposite end to the crownwheel. Refer to Figure 33.

AB AC

54. Apply Loctite 574 to the drivehead mating face, then install the brake piston housing. Refer to Figure 33.

55. Make sure that the mark made between the drivehead and the brake piston housing at the time of disassembly is aligned. Refer to Figure 33.

AA Oil seal AB Coupling yoke AC Stake nut

56. Install the crownwheel/ differential assembly into the drivehead. Refer to Figure 32.

48. Install the coupling yoke and the new stake nut.

Refer to Figure 30.

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22 - Drivehead 00 - General

Figure 32.

60. Adjust the differential side nuts to give a bearing pre-load of the specified value.

Torque: 1.13 –2.26 N·m

D

61. Measure the pre-load by taking another rolling torque reading and subtracting the torque figure measured at step 50. The difference is the bearing pre-load.

62. Measure the crownwheel backlash, it should be within the specified limit.

Dimension: 0.17 –0.28 mm 63. Adjust the differential side nuts by equal amounts when you change the backlash.

64. When the backlash and pre-load are both correct, install the side nut locking pins. Refer to Figure 33.

D Crownwheel/ differential assembly 57. Install the other side brake piston housing onto the drivehead. Refer to Figure 33.

65. Check the tooth marks to make sure that the crownwheel and pinion are set correctly.

Refer to Front Drivehead, Crownwheel- Check (Operation).

Refer to: PIL 27-22-06.

Figure 34.

Figure 33.

C AD

B

A

Table 11. Spacer Selection Example Value 14.20 0.25 13.95 0.04

(1)

A B C AD

Capscrew Brake piston housing Side nut locking pin Differential side nut

58. Install the capscrews. Refer to Figure 33.

59. Tighten the capscrews to the correct torque value. Refer to Figure 33.

27 - 34

Temporary spacer size Subtract end float Total Subtract tolerance and pre-load Result 13.91 Use next smallest spac- 13.90 er

(1) All the values are in millimetre (mm).

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22 - Drivehead 00 - General

Table 12. Torque Values Item M T AC A

Description Bolt Pinion shaft adaptor Stake nut Capscrew

Nm 46 50 250 56

Consumables Description JCB Multi-Gasket JCB Threadlocker and Sealer (Medium Strength)

8. Drive off the taper roller bearing cone 1 from the crownwheel differential case half.

9. Remove the differential assembly from the carrier.

10. Mark the position of the drive yoke on the splined shaft.

(For: 55 Series (1 Piece Axle)) Special Tools Description Drive Coupling Spanner Setting Tool Kit Spacer Kit Spacer Kit Torque Wrench (10-100Nm) Support Bracket

7. Remove the bearing outer race 1 and bearing outer race 2 from the drivehead carrier bores.

11. Use the special tool to prevent the drive yoke from rotating and remove the pinion nut.

Part No. 892/00812

Qty. 1

892/00918 921/52600 921/53300 993/70111

1 1 1 1

997/11000

1

Part No. 4102/1212 4101/0250 4101/0251

Size 0.05 L 0.01 L 0.05 L

Special Tool: Drive Coupling Spanner (Qty.: 1) 12. Remove the drive yoke.

13. Remove the pinion shaft from the drivehead carrier.

14. Prise the pinion oil seal out of the bore.

15. Remove the pinion tail bearing.

16. If necessary, remove the bearing outer race 3.

17. If necessary, remove the bearing cup from the opposite side of the drivehead carrier and remove the pinion shims.

18. Remove the spacer and the taper roller bearing cone 3 from the pinion.

Disassembly The drivehead consists of the drivehead carrier and pinion assembly, and the differential unit. A separate disassembly procedure is given for each sub assembly.

Disassemble the Drivehead Carrier

Disassemble necessary)

the

differential

unit

(If

1. For LSD (Limited Slip Differential) Refer to Front Differential, Disassemble and Assemble.

2. Remove the differential assembly retaining bolt and separate the case half 1 and case half 2.

1. Drain the oil from the axle centre case.

2. Completely remove both hub assemblies with the driveshafts.

3. Mark the installation position of the drivehead carrier with respect to the axle case.

4. Remove the drivehead carrier retaining bolt and then remove the drivehead carrier from the axle case.

5. Clean the drivehead carrier and axle case mating faces.

3. Remove the side gears and the thrust washer 1 (2 off each).

4. Remove the bevel gears and thrust washer 2 (4 off each) from the trunnion pins.

5. Remove the taper roller bearing cone 2 from the differential case half.

6. Remove the Verbus-ripp bolts.

7. Remove the crownwheel from the differential case half.

6. Pull out the tension pin 1 and tension pin 2, and remove the castellated nut 1 and castellated nut 2.

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Figure 35.

D

L

K

T M G

E

Q

C

P

F

H

W

R

S

N

J

N

V

A

B AG

U AD AE

Z

AC AA

AB

X

27 - 36

AF

Y

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27 - Driveline

22 - Drivehead 00 - General

housing halves are also matched. Do not use unmatched halves.

Table 13.

Item A B C D E F G H J K L M N P Q R S T U V W X Y Z AA AB AC AD AE AF AG

Description Drivehead carrier retaining bolt Drivehead carrier Tension pin 1 Tension pin 2 Castellated nut 1 Castellated nut 2 Bearing outer race 1 Bearing outer race 2 Taper roller bearing cone 1 Differential assembly Differential assembly retaining bolt Case half 1 Case half 2 Side gear Thrust washer 1 Bevel gear Thrust washer 2 Taper roller bearing cone 2 Verbus-ripp bolt Crownwheel Trunnion pin Pinion nut Drive yoke Pinion shaft Pinion oil seal Pinion tail bearing Bearing outer race 3 Bearing cup Drive pinion shim Spacer Taper roller bearing cone 3

Assembly

Assemble the differential unit (if necessary) 1. For LSD Refer to Front Differential, Disassemble and Assemble.

2. Assemble the trunnion pin, bevel gear 1 and the bevel gear 2 then the thrust washer 1 and thrust washer 2 into differential half case 2.

3. Put the differential half case 1 onto the half case 2. Make sure you align them properly.

4. Apply sealant to the differential assembly retaining bolt and then install it.

Consumable: JCB Threadlocker and Sealer (Medium Strength) 5. Tighten the bolt to the correct torque value.

6. Check the gears for free rotation.

7. Use new Verbus-ripp bolts to install the crownwheel.

8. Tighten the bolt to the correct torque value. Refer to table1.

Assemble the drivehead carrier 1. Measure the correct thickness for the seam.

Refer to Front Drivehead, Pinion Gear- Calibrate.

Refer to: PIL 27-22-09.

2. Install the shim behind the new bearing cup.

3. Install the new pinion head bearing cone onto the pinion.

4. Install the pinion and bearings into the drivehead case.

5. Install the largest available solid spacer (14.20 mm).

Special Tool: Spacer Kit (Qty.: 1) 6. Apply a coat of oil and then install the pinion tail bearing.

7. Do not install the oil seal at this stage.

The procedure below refers to the following aspects of the drivehead assembly, which are covered separately in detail.

8. Install the special tool sleeve and the special pinion shaft adaptor from the setting kit.

• •

9. Tighten the adaptor to the correct torque value.

Pinion depth setting Crownwheel and pinion meshing

Both the crownwheel and pinion and the bevel gear 1 and bevel gear 2 are matched and should be replaced as a set, if any of their components are damaged or excessively worn. The two differential 27 - 37

Special Tool: Setting Tool Kit (Qty.: 1)

10. Make sure that the pinion is free to rotate and there is end float, this will prevent any damage to the bearing. If the pinion is not free to rotate or there is no end float at this stage check the

9823/0100-1

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22 - Drivehead 00 - General

Figure 37.

bearing is installed properly. Also check that the correct size spacer is installed.

11. Use two (M10x30) nuts and bolts to install the special bracket on the drivehead housing.

AN

Special Tool: Support Bracket (Qty.: 1) Figure 36.

AL AK

AM

AJ AH AM DTI AN Torque wrench 16. Set the torque wrench to the specified value and measure the end float while you rotate the shaft.

AH AJ AK AL

Torque: 35 N¡m Special Tool: Torque Wrench (10-100Nm) (Qty.: 1)

Special tool sleeve Adaptor Special bracket Support pillar

17. To select the right size spacer do the following steps. Refer to Table 16.

17.1. Subtract the end float obtained in step 16 from the solid spacer thickness value (14.20 mm).

12. Install the special support pillar on the bracket so that the fork end engages with the adaptor.

17.2. Subtract 0.04mm to allow for theoretical bearing tolerance and pre-load.

13. Make sure that the fork is centrally located on the adaptor.

17.3. The result is the size of spacer to be installed from the solid spacer setting kit.

14. If necessary, align the bracket again.

Special Tool: Spacer Kit (Qty.: 1)

15. Install a DTI. Make sure that the DTI is mounted on the drivehead and not on the bracket.

17.4. If there is no spacer of this size, then install the next nearest size spacer.

18. Remove the sleeve and the temporary spacer.

19. Install the correct size spacer from the solid spacer setting kit.

20. Make sure that you do not damage the outer bearing.

21. Again install the sleeve and then install the adaptor.

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27 - Driveline

22 - Drivehead 00 - General

22. Tighten the adaptor to the correct torque value, to protect against bearing damage while spacer selection is verified making sure the pinion is free to rotate.

41. Measure the backlash between the crownwheel and the pinion and it should be within the specified limit.

23. Check there is no end float and the pinion is free to turn smoothly by hand.

42. When altering the backlash adjust both the castellated nut in equal amounts.

24. Remove the adaptor and then install the nut.

43. When the backlash and pre-load are both correct, install the tension pin 1 and tension pin 2.

25. Make sure that the rolling torque is less than 2.0 Nm, if the rolling torque exceeds 2.0 Nm, then check that the shaft is assembled correctly or not.

26. If the pinion is not free to rotate, check the correct size spacer has been installed.

Length/Dimension/Distance: 0.17 –0.28 mm

44. Check the tooth marks to verify that the crownwheel and the pinion are set correctly.

45. Apply JCB Multigasket to the mating faces of the drivehead carrier and the axle case.

27. If the rolling torque measured at step 25 is too high, install the next larger size spacer. If the rolling torque is too low, install the next smallest size spacer. If a correct spacer is not available from the range, check that drivehead is assembled correctly.

46. Install the drivehead carrier to the axle case with the crownwheel towards the short driveshaft.

28. Remove the adaptor and the sleeve.

48. Tighten the bolt to the correct torque value.

29. Lubricate the seal lips and then install the new oil seals.

49. Reassemble assemblies.

Consumable: JCB Multi-Gasket

47. Install the drivehead carrier retaining bolts.

30. Install the coupling yoke and the new stake nut.

31. Gradually tighten the stake nut up to the specified torque value, while occasionally rotating the coupling yoke.

Torque: 250 N·m

Torque: 2.3 –3.4 N·m 33. The nut tightening torque value can be increased to a maximum of 300 Nm but the pinion rolling torque does not exceed the maximum of 3.4 Nm.

Item A

assembly

onto

Item A U

the

36. Push the taper roller bearing onto the spigot of the differential half case2.

37. Install the bearing outer race 1 and bearing outer race 2.

38. Install the castellated nut 1 and castellated nut 2 to the drivehead carrier.

39. Do not install the tension pin 1 and tension pin 2 at this stage.

40. Adjust the castellated nut to give an increase in input pinion rolling torque of between 1.36 and 2.5 Nm more than that specified in Step25.

27 - 39

and

hub

Description Nm Drivehead carri- 98 er retaining bolt Verbus-ripp bolt 94

Table 15. Torque Settings (70 and 80 Series)

34. Finally stake the nut into the slot.

35. Install the differential drivehead carrier.

driveshafts

Table 14. Torque Settings (55 Series)

U

32. If the correct size spacer is selected then the pinion rolling torque should with in the specified limit.

both

Description Nm Drive head car- 166 rier retaining bolt 'Verbus Ripp' 200 bolt Table 16. Spacer Selection Example Value 14.20 0.25 13.95 0.04

(1)

Temporary spacer size Subtract end float Total Subtract tolerance and preload Result 13.91 Use next smallest spac- 13.90 er

(1) All the values are in millimetre (mm).

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22 - Drivehead 00 - General

Table 17. Torque Values Item L AJ

27 - 40

Description Differential assembly retaining bolt Adaptor

Nm 46 50

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22 - Drivehead

06 - Crownwheel

06 - Crownwheel

Introduction

Introduction .................................................... 27-41 Check (Operation) ......................................... 27-42

A crown wheel is a rotating gear wheel with teeth set at right angles to its plane, it is usually matched with a pinion gear that meshes with the crown wheel. They are mainly used in vehicles to maintain a forward movement.

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27 - Driveline

22 - Drivehead

06 - Crownwheel

Check (Operation)

Figure 40.

Crownwheel and Pinion Meshing 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.

1. Correct tooth marking.

Figure 38.

2. Pinion too deeply in mesh. Move the crown wheel towards the pinion to correct the backlash.

Figure 39.

3. Pinion too far out of mesh. Move the crown wheel away from the pinion to correct the backlash.

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27 - Driveline

22 - Drivehead

09 - Pinion Gear

09 - Pinion Gear

Introduction

Introduction .................................................... 27-43 Calibrate ........................................................ 27-44

A pinion gear is a small gear that meshes with a larger crownwheel. They are mainly used in vehicles to maintain a forward movement.

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27 - Driveline

22 - Drivehead

09 - Pinion Gear

Calibrate Special Tools Description Shim Kit

Part No. 921/M0229

and record the height. The bearing cups and rollers are matched sets. Always keep the bearing assemblies together. Make sure that you measure only the inner bearing.

Qty. 1

Figure 43.

Pinion Depth Setting

E

Determine the pinion depth setting shim size as follows: 1. Note the deviation figure etched on the pinion and the deviation figure on the drivehead housing. Both figures are in units of 0.01 mm.

Note: The pinion depth may be etched on the gear face or on the rear of a gear tooth.

Special Tool: Shim Kit (Qty.: 1)

E Inner bearing height

Shim Size Calculation Example Table 18. Calculation 1.

Actual Drivehead Case Size Item

Figure 41.

D

A

Typical Figures 187.6 mm

B

-0.14 mm

Sum of A and B 187.46 mm

Description Nominal drivehead case size, fixed at the factory Drivehead case deviation, marked on the case Actual drivehead case size

Table 19. Calculation 2. Actual Pinion and Bearing Size Item D Pinion depth Figure 42.

C

Typical Figures 150.0 mm

D

0.10 mm

E

36.6 mm

Sum of C, D and E

186.70 mm

Description Nominal pinion length, fixed at the factory Pinion deviation, marked on the pinion Bearing size, inner pinion bearing Actual pinion and bearing size

Table 20. Calculation 3. Shim Size = Calculation 1 - Calculation 2 Typical Figures 187.46 - 186.70 = 0.76mm

B Deviation figure

Description Select the nearest shim size from the shim kit.

2. Assemble the pinion inner bearing and its cup on a flat surface. Lightly oil and rotate the bearing before measurement. Make sure that the bearing cup is square and measure 27 - 44

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24 - Differential

24 - Differential Contents

Page No.

27-24-00 General ........................................................................................................................... 27-47

27 - 45

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27 - 45

Notes:

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24 - Differential 00 - General

00 - General Introduction ....................................................

Component Identification ...............................

Check (Condition) ..........................................

Disassemble and Assemble ..........................

Introduction 27-47 27-49 27-53 27-54

A differential is a particular type of simple planetary gear train.

The differential couples the drive shaft to half-shafts that connect to the rear driving wheels. The purpose of the differential is to allow a speed differential between the inner and outer wheel while being driven by the input shaft. In its most common form, the differential consists of a pinion and ring and planetary bevel gears to connect the output shafts.

The axle can have the following type of differentials.

1. Open Differential.

2. LSD (Limited Slip Differential).

Open Differential A standard differential, or what is referred to as an open carrier. A conventional open differential always supplies close to equal (because of limited internal friction) torque to each side. The differential gearing allows the outer drive wheel to rotate faster than the inner drive wheel during a turn. This is necessary when the vehicle turns, making the wheel that is travelling around the outside of the turning curve roll farther and faster than the other.

In a standard [open type] differential, the rotational velocity of the input shaft is the average of the rotational velocity of the output shafts under normal traction conditions. Therefore, increasing the speed of one output shaft will decrease the speed of the other output shaft.

The problem is an open differential always tries to balance the torque. It means that if the spider gears are pushing on both drive gears and one of them offers lots of resistance and the other side offers no resistance then it will try to find a balance where both sides are receiving almost no torque at all. All the rotational energy is guided to the side with the least resistance. In the end, that side spins very fast and the pressure on each drive gear is the same. Almost no torque is needed to spin one wheel, and since the open differential always sends the same amount of torque to both output shafts, almost no torque is going to the other side as well.

Limited Slip Differential (LSD) In the most basic sense, a LSD equalizes the difference in either speed between output shafts or applied torque between output shafts to maintain traction in adverse or performance conditions. The benefits of installing an LSD are: 1. Enhanced traction in snow, gravel, and sand.

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24 - Differential 00 - General

2. More predictable handling at the limits of grip.

This type behaves as an open differential unless one wheel begins to spin and exceeds that threshold.

The LSD will remain open unless enough torque is applied to cause one wheel to lose traction and spin, at which point it will engage.

An LSD can use clutches when engaged, or may also be a solid mechanical connection like a locker or spool. It is called limited slip because it does just that; it limits the amount that one wheel can slip.

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24 - Differential 00 - General

Component Identification For: 55 Series (3 Piece Axle), Limited Slip Differential (LSD) ....................... Page 27-49 For: Limited Slip Differential (LSD) ................................................... Page 27-50 For: 55 Series (1 Piece Axle), Limited Slip Differential (LSD) ....................... Page 27-51 For: Limited Slip Differential (LSD) ................................................... Page 27-52

(For: 55 Series (3 Piece Axle), Limited Slip Differential (LSD)) Figure 44. Limited Slip Differential (LSD)

E

F

H

J

K

A

N

M G

P K

C

J

H

G

L

F D B

A C E G J L N

Verbus-ripp bolts Bolts Differential assembly case Shims Friction plates Side gears Bevel gears

27 - 49

B D F H K M P

Crownwheel Differential assembly case Shims Counter plates Pressure plates Trunnion pins Thrust washers

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24 - Differential 00 - General

(For: Limited Slip Differential (LSD)) Figure 45.

AA

R

M N

L

H

T

Q

G1

S

S

T

Q

P R

G2

K J

X

AE AB

C

D1

AD

AC F

C

Y

E

Z W F

U AA

A

B

D2

V A C D2 F G2 J

Bolt 1 Roll pin Castellated nut 2 Bearing cone Differential case half Crownwheel

27 - 50

B D1 E G1 H K 9823/0100-1

Drivehead carrier Castellated nut 1 Bearing cup Differential case half Verbus-ripp bolt Bolt 2 27 - 50

27 - Driveline

24 - Differential 00 - General

L N Q S U W Y AA AC AE

M P R T V X Z AB AD

Trunnion pin Thrust washer Shim 1 Friction plate Stake nut Drive flange Collapsible spacer Pinion tail bearing Pinion head bearing cap Bush

Planet gear Side gear Counter plate Pressure plate Washer Pinion Oil seal Pinion head bearing cone Shim 2

(For: 55 Series (1 Piece Axle), Limited Slip Differential (LSD)) Figure 46.

E

F

H

J

K

A

N

M G

P K

C

J

H

G

L

F D B

A C E G J L N

Verbus-ripp bolts Bolts Differential assembly case Shims Friction plates Side gears Bevel gears

27 - 51

B D F H K M P

Crownwheel Differential assembly case Shims Counter plates Pressure plates Trunnion pins Thrust washers

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24 - Differential 00 - General

(For: Limited Slip Differential (LSD)) Figure 47.

E

F

H

J

K

A

N

M G

P K

C

J

H

G

L

F D B

A C E G J L N

Verbus-ripp bolts Bolts Differential assembly case Shims Friction plates Side gears Bevel gears

27 - 52

B D F H K M P

Crownwheel Differential assembly case Shims Counter plates Pressure plates Trunnion pins Thrust washers

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24 - Differential 00 - General

Check (Condition) 1. For JCB axles only: measure and note the thickness of the friction plates, the result must not be less than the specified dimension.

Dimension: 1.25 mm 2. Check the condition of the friction material, which should be even over both surfaces. If in doubt, discard the set (friction and counter plates).

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24 - Differential 00 - General

Disassemble and Assemble For: Limited Slip Differential (LSD) ................................................... Page 27-54 For: 55 Series (1 Piece Axle), 55 Series (3 Piece Axle), Limited Slip Differential (LSD) ................................................... Page 27-57 For: Limited Slip Differential (LSD) ................................................... Page 27-60

(For: Limited Slip Differential (LSD))

2. Remove the crownwheel.

3. Put marks on the two halves of the differential housing before disassembly to make sure of correct assembly.

4. Remove the capscrews.

5. Disengage the two halves of the differential and remove the following components:

The numerical sequence shown on the illustration is intended as a guide for disassembly.

5.1. Trunnion pins.

The number of friction and counter plates shown in the illustration is typical only. The actual number of plates is determined by the axle variant.

5.3. Bevel gears.

Important: The crownwheel and pinion are matched and should be replaced as a pair if either one is damaged or excessively worn. The two halves of the differential housing are also matched as are the differential side gears and bevel gears, do not use unmatched halves or gears.

Disassemble 1. Use a heavy duty socket to remove the verbusripp bolts. Discard the bolts.

27 - 54

5.2. Side gears.

5.4. Spherical washers.

5.5. Pressure plates.

5.6. Counter plates.

5.7. Friction plates.

5.8. Shims.

6. Make a note of the relative positions of the friction plates, counter plates and spacers before disassembly, they must be installed in the same positions.

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24 - Differential 00 - General

Figure 48. Limited Slip Differential (LSD)

E

F

H

J

K

A

N

M G

P K

C

J

H

G

L

F D B

A C E G J L N

B D F H K M P

Verbus-ripp bolts Bolts Differential assembly case Shims Friction plates Side gears Bevel gears

Crownwheel Differential assembly case Shims Counter plates Pressure plates Trunnion pins Thrust washers

Assemble

1.6. Thrust washers.

1. Install the following components into the crownwheel half of the differential assembly: 1.1. Trunnion pins.

1.2. Side gears with pressure plates.

1.3. Counter plates.

1.4. Friction plates.

1.5. Bevel gears.

27 - 55

2. Do not install the shims at this stage.

3. Align the two halves of the differential assembly with the bolts. Make sure that the marks made during disassembly are aligned.

4. Use a DTI (Dial Test Indicator) (or feeler gauges), with two screwdrivers or suitable levers, gently apply pressure to prise the side gear away from the trunnion pins.

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24 - Differential 00 - General

Figure 49.

5. Measure and record the end float of the side gear.

assembled differential as this is only an initial setting figure which allows for bedding in.

6. Turn the differential assembly over and repeat steps 4 and 5 for the second side gear.

7. Disassemble the differential assembly.

8. Add shims to give an end float between the specified range.

Length/Dimension/Distance: 0.1 –0.2 mm 8.1. Shimming must be carried out whenever the differential is dismantled, however, the end float 0.1 and 0.2 mm (0.004 and 0.008 in) can be exceeded on previously

8.2. Select the minimum number of shims to give the correct thickness.

9. Do the steps 4 to 6 again.

10. If the end float is correct, tighten the bolts to the correct torque value.

11. Install the crownwheel with new verbus-ripp bolts.

12. Tighten the verbus-ripp bolts to the correct torque value.

Table 21. Torque Values Item A

Nm 94

A C

56

(1) (2)

200

(1) The torque value is applicable for the 40 Series drivehead.

(2) The torque value is applicable for the 85 Series drivehead.

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24 - Differential 00 - General

(For: 55 Series (1 Piece Axle), 55 Series (3 Piece Axle), Limited Slip Differential (LSD))

3. Put marks on the two halves of the differential housing before disassembly to make sure of correct assembly.

The numerical sequence shown on the illustration is intended as a guide for disassembly.

4. Remove the capscrews.

5. Disengage the two halves of the differential and remove the following components:

The number of friction and counter plates shown in the illustration is typical only. The actual number of plates is determined by the axle variant.

5.1. Trunnion pins.

Important: The crownwheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn. The two halves of the differential housing are also matched as are the differential side gears and bevel gears, do not use unmatched halves or gears.

5.2. Side gears.

Disassemble

5.7. Friction plates.

1. Use a heavy duty socket to remove the verbusripp bolts. Discard the bolts.

5.8. Shims.

5.3. Bevel gears.

5.4. Spherical washers.

5.5. Pressure plates.

5.6. Counter plates.

6. Make a note of the relative positions of the friction plates, counter plates and spacers before disassembly, they must be installed in the same positions.

2. Remove the crownwheel.

Figure 50. Limited Slip Differential (LSD)

E

F

H

J

K

A

N

M G

P K

C

J

H

G

L

F D B

A C E G J

Verbus-ripp bolts Bolts Differential assembly case Shims Friction plates

27 - 57

B D F H K

Crownwheel Differential assembly case Shims Counter plates Pressure plates

9823/0100-1

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24 - Differential 00 - General

L Side gears N Bevel gears

27 - 58

M Trunnion pins P Thrust washers

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24 - Differential 00 - General

Assembly

1.6. Thrust washers.

1. Install the following components into the crownwheel half of the differential assembly: 1.1. Trunnion pins.

1.2. Side gears with pressure plates.

2. Do not install the shims at this stage.

3. Align the two halves of the differential assembly with the bolts. Make sure that the marks made during disassembly are aligned.

4. Use a DTI (or feeler gauges), with two screwdrivers or suitable levers, gently apply pressure to prise the side gear away from the trunnion pins.

1.3. Counter plates.

1.4. Friction plates.

1.5. Bevel gears.

Figure 51.

5. Measure and record the end float of the side gear.

assembled differential as this is only an initial setting figure which allows for bedding in.

6. Turn the differential assembly over and repeat steps 4 and 5 for the second side gear.

7. Disassemble the differential assembly.

8. Add shims to give an end float between the specified range.

Length/Dimension/Distance: 0.1 –0.2 mm 8.1. Shimming must be carried out whenever the differential is dismantled, however, the end float 0.1 and 0.2 mm (0.004 and 0.008 in) can be exceeded on previously

27 - 59

8.2. Select the minimum number of shims to give the correct thickness.

9. Do the steps 4 to 6 again.

10. If the end float is correct, tighten bolts to the correct torque value.

11. Install the crownwheel with new verbus-ripp bolts.

12. Tighten the verbus-ripp bolts to the correct torque value.

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24 - Differential 00 - General

Table 22. Torque Values Item 1

Nm 94

1 3

56

(1)

200

(2)

(1) The torque value is applicable for the 55 Series drivehead.

(2) The torque value is applicable for the 80 Series drivehead.

(For: Limited Slip Differential (LSD)) Special Tools Description Bearing Press Drive Coupling Spanner Adaptor Bearing Adaptor Consumables Description JCB Multi-Gasket

8. Remove the roll pins and then remove the castellated nuts.

9. Remove and discard the bearing cups.

Part No. 892/00179 892/00812

Qty. 1 1

992/07608 992/07609

1 1

Part No. 4102/1212

Size 0.05 L

10. Remove the bearings.

WARNING! A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the machine being started while you are beneath it.

1. Drain the oil from the axle hubs.

2. Remove the following components from both the hubs:

the

12. Use the service tool to remove the drive flange.

Special Tool: Drive Coupling Spanner (Qty.: 1) 13. Remove the pinion and the collapsible spacer.

14. Remove the oil seal and pinion tail bearing.

15. Remove the pinion head bearing cone from the pinion.

16. Remove the pinion head bearing cap along with its shims 2.

17. Use a heavy duty socket to remove the verbusripp bolts. Discard the bolts.

18. Remove the bolt 2.

20. Remove the capscrews.

21. Disengage the two halves of the differential and remove the following components:

2.2. Brake pressure plate.

21.1. Trunnion pins.

2.3. Brake friction plates.

21.2. Side gears.

2.4. Brake counter plates.

21.3. Planet gears.

3. Remove the driveshaft.

21.4. Thrust washers.

4. Remove the propshaft.

21.5. Pressure plates.

21.6. Counter plates.

5. Drain the oil from the differential casing.

21.7. Friction plates.

6. Remove the bolts 1.

27 - 60

Discard

19. Put marks on the two halves of the differential housing before disassembly to make sure of correct assembly.

Disassemble

7. Lift the drivehead carrier from the casing.

cones.

11. Remove the differential assembly from the drivehead when the bearings have been removed from both sides.

As the drivehead cannot be disassembled while installed on the machine, we recommend that the complete axle is removed.

2.1. Planet gear carrier.

bearing

21.8. Shims.

22. Inspect the condition and security of the bushes.

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24 - Differential 00 - General

22.1. Note: Later type differential assemblies are not installed with the bushes, instead,

the differential case halves are machined so that they support the driveshafts.

Figure 52.

AA

R

M N

L

H

T

Q

G1

S

S

T

Q

P R

G2

K J

X

AE AB

C

D1

AD

AC F

C

Y

E

Z W F

U AA

A

B

D2

V A C D2 F G2 J

Bolt 1 Roll pin Castellated nut 2 Bearing cone Differential case half Crownwheel

27 - 61

B D1 E G1 H K 9823/0100-1

Drivehead carrier Castellated nut 1 Bearing cup Differential case half Verbus-ripp bolt Bolt 2 27 - 61

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24 - Differential 00 - General

L N Q S U W Y AA AC AE

Trunnion pin Thrust washer Shim 1 Friction plate Stake nut Drive flange Collapsible spacer Pinion tail bearing Pinion head bearing cap Bush

27 - 62

M P R T V X Z AB AD

9823/0100-1

Planet gear Side gear Counter plate Pressure plate Washer Pinion Oil seal Pinion head bearing cone Shim 2

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24 - Differential 00 - General

Assemble Make sure all bearings are lightly oiled before installation and setting. Make sure that the bearings are rotated when they are being set.

1. Install the following components into the crownwheel half of the differential assembly:

4. Attach the two halves of the differential assembly with the bolts 2. Make sure the marks made during disassembly are aligned.

5. Use a DTI (or feeler gauges), with two screwdrivers or suitable levers, gently apply pressure to prise the side gear away from the trunnion pins.

Figure 54.

1.1. Trunnion pins.

1.2. Side gears with pressure plates.

1.3. Counter plates.

1.4. Friction plates.

1.5. Planet gears.

1.6. Thrust washers.

2. The counter plates and friction plates should be installed alternatively, as shown. However, some axles which incorporate differential assemblies containing 9-friction faces require a unique configuration. Before assembling these parts, identify the correct configuration for your machine.

Figure 53.

S

R

6. Measure and record the end float of the side gear.

S

7. Turn the differential assembly over and do the steps 5 and 6 for the second side gear.

8. Disassemble the differential assembly.

9. Add shims to give an end float between the specified range.

T

9.1. For new plates.

R

Dimension: 0.1 –0.2 mm 9.2. For old plates.

S

Dimension: 0.2 –0.5 mm 10. Do the steps 5 to 7 again.

11. If the end float is correct, tighten the bolts to the correct torque value.

T R Counter plate S Friction plate T Pressure plate

R

12. Install the crownwheel with new verbus-ripp bolts.

13. Tighten the verbus-ripp bolts to the correct torque value.

14. Measure the pinion depth setting.

3. Do not install the shims 1 at this stage.

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24 - Differential 00 - General

15. Install a new pinion head bearing cone into the pinion with suitable press and adaptors.

Special Tool: Bearing Press (Qty.: 1) Special Tool: Adaptor (Qty.: 1) Special Tool: Bearing Adaptor (Qty.: 1) 16. Install the new collapsible spacer onto the pinion.

17. Apply oil on the pinion head bearing and install the pinion in the housing.

17.1. Before you install the pinion, make sure that the pinion matches the crownwheel.

18. Apply oil on the pinion tail bearing.

19. Use a suitable drift and tap the tail bearing into its position in the housing.

30. Adjust castellated nut 2 until there is no end-float and no pre-load. Make sure that the bearings are bedded in by rotating in each direction.

31. Tighten castellated nut 2 by a further 4 castellations to set pre-load. Make sure that the correct backlash is maintained.

32. Install the roll pins.

33. Apply sealant to the mating surfaces of the drive head carrier and the axle casing.

Consumable: JCB Multi-Gasket 34. Install the drivehead carrier to the axle casing with the crownwheel towards the long driveshaft.

35. Install the bolts 1.

36. Tighten the bolts 1 to the correct torque value.

20. Put a new oil seal into the housing.

37. Assemble the driveshafts and hub assemblies.

20.1. Lubricate the seal lips.

21. Install the drive flange with a new stake nut and washer.

38. Fill the hubs and the differential with the correct grade of oil.

22. Tighten the stake nut into the collapsible spacer until the end float is almost zero, and then measure the seal drag torque.

39. Install the propshaft.

22.1. The seal drag torque should be within the specified range.

Torque: 0.4 –0.75 N·m 23. Continue to tighten the stake nut to collapse the spacer to get a rolling torque of the specified range.

40. Fill the hubs and the differential with the correct grade of oil.

Table 23. Torque Values Item A K H

Description Bolt 1 Bolt 2 Verbus-ripp bolt

Nm 56 56 94

Torque: 1.7 –2.8 N·m 23.1. Rotate the flange in each direction to bed in the bearings before measuring.

23.2. Note: If the specified rolling torque is exceeded, the collapsible spacer will be distorted. Replace the spacer and start again.

24. Stake the nut when the pre-load is correct.

25. Install the differential assembly (without the bearings) into the drivehead.

26. Install the bearing cones onto the spigots.

27. Apply oil on the bearings and install the bearing cups and the castellated nuts.

28. Do not install the roll pins at this stage.

29. Adjust castellated nut 1 on the crownwheel side until you get a backlash value within the specified range.

Length/Dimension/Distance: 0.13 –0.2 mm

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Page No.

27-27-00 General ........................................................................................................................... 27-67

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Notes:

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27 - Driveline

27 - Hub

00 - General

00 - General Introduction ....................................................

Component Identification ...............................

Drain and Fill .................................................

Calibrate ........................................................

Disassemble and Assemble ..........................

Introduction 27-67 27-68 27-70 27-73 27-74

The hub is the part of the axle where the wheel is mounted and where the axle shaft (if installed) passes through.

Some hubs are not driven and rotate due to motion of the machine and some driven hubs may also have reduction gearing installed.

The hub may also be designed to allow steering of the wheels and/or incorporate brakes.

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00 - General

Component Identification Unit Identification

Main Component Identification Figure 57.

The axle serial number is stamped on the unit identification plate as shown. When you make an order for parts replacement, always give the details mentioned on the unit identification plate. In the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

G

Figure 55.

H

A B C

A

J K

D

A Identification plate Figure 56.

L

E F

M

Table 24.

Item no A B

A Identification plate

27 - 68

C D E F G H J K L M

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Description Annulus ring Planet gear assembly (x3) Thrust pad Sun gear Planet gear carrier Wheel stud (x5) Bearing carrier Hub swivel Driveshaft Oil seal Wheel bearing (inner) Wheel bearing (outer)

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00 - General

Sectional Drawing Figure 58.

13

10 7 11

5

3

4

57

1

12 14 8 16

18

15 17 20 19

23 26

9

22

Table 25.

Item no 1 3 4 5 7 8 9 10 11 12 13 14 15 16 27 - 69

Description Swivel hub Bearing (taper roller) Oil seal Bearing carrier Annulus carrier Dowels Bolt Verbus-ripp Annulus ring Circlip (internal) Planet gear Planetary hub carrier Bearing Circlip (L-shaped) Circlip (external)

24 25

Item no 17 18 19 20 22 23 24 25 26 57

9823/0100-1

Description Thrust pad Driveshaft Sun gear Circlip (external) O-ring Drain plug Bearing Oil seal Spacer (55 Series hub only) Cover plate

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27 - Driveline

27 - Hub

00 - General

Drain and Fill Check the hub oil level of one wheel at a time.

Complete the steps below to check the hub oil.

1. Make the machine safe. Refer to (PIL 01-03).

2. Set the machine level with the wheels above the ground.

2.1. Use suitable lifting equipment to lift the machine axles to the same level.

3. Set the hub oil level mark to the horizontal position.

4. Apply the park brake.

5. Set the transmission to the neutral position.

6. Lower the attachments to the ground.

7. Stop the engine and remove the ignition key.

8. Clean the area around the hub plug.

9. Remove the hub plug.

10. Check the oil level of the hub.

10.1. The hub oil level must be level with the bottom surface of the plug hole.

3.1. Turn the wheel manually to get the hub oil level mark to the horizontal position.

3.2. The specified tolerance is permitted above or below the oil level mark horizontal position.

Length/Dimension/Distance: 5 mm

10.2. If necessary, add the correct axle oil. Refer to (PIL 75).

11. Clean the plug before you install it.

12. Install the hub plug and tighten to the correct torque.

Figure 59.

A

12.1. To Make sure you use the correct torque tightening information, identify the correct axle for your machine. Refer to Figure 60. and Refer to Figure 61.

B

12.2. Make sure you identify the correct plug for your machine. Then use the related torque information. Refer to Figure 62. and Refer to Figure 63.

E D

A B C D E

27 - 70

C

Wheel Hub Plug Level mark Tolerance 5 mm

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00 - General

Figure 60. JCB Axles With Inboard Brakes (If installed) B

A

B

A Axle drain plug 1 location Table 26. JCB Axles With Inboard Brakes Type of Differential Plug InHub Plug Installed stalled on Your Machine Axle drain plug 1 with hexagonal Taper plug (3/4 in NPSF) head and bonded washer Axle drain plug 1 with tapered plug Taper plug (3/4 in BSP)

Hub Plug Torque (Nm) 50 80

Figure 61. JCB Axles With Braked Hubs (If installed) D D

E

D Drain plug

E Axle drain plug 2 location Table 27. Axles With Braked Hubs

Type of Differential Plug InHub Plug Installed stalled on Your Machine Axle drain plug 2 with hexagonal Plug (M22) head and bonded washer Axle drain plug 2 with tapered plug Taper plug (3/4 in BSP)

Hub Plug Torque (Nm) 37.5 80

Figure 62. Hexagonal Head Plug and Bonded Washer (Prior to January 2011)

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Figure 63. Taper Plug (If installed) (January 2011 Onwards)

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Calibrate Refer to the relevant Disassemble and Assemble procedure (PIL 27-27).

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00 - General

Disassemble and Assemble Special Tools Description Heavy Duty Socket 19mm A/F x 3/4 in Drive Wheel Hub Service Kit Reaction Plate M14 Studs Reaction Plate

Part No. 892/00333

Figure 64.

Qty. 1

F G

892/01092 998/M1374

1 4

998/M1375

1

D B

Disassemble WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end.

Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

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

B D G F

Planet gear carrier Planet gear Driveshaft thrust pad External circlip 1

5.1. Remove the external circlip 1.

The illustrations in this procedure show the axle removed from the machine but the hubs can be disassembled without removing the axle. Refer to Figure 70.

5.2. Remove the planet gear.

5.3. The driveshaft thrust pad is drilled and tapped for removal purposes. Use a suitable M6 screw to extract the thrust pad from inside the planet gear carrier.

1. Drain the oil from the hub.

2. Remove the screws.

6. Remove the external circlip 2.

3. Remove the planet gear carrier from the bearing carrier.

7. Remove the sun gear from the driveshaft.

4. Remove and discard the O-ring.

5. Remove the planet gears only if they are damaged. Note: Planet gears can only be replaced as an assembly which contains the gear, bearing, and two L-shaped circlips. Refer to Figure 64. and Refer to Figure 69.

27 - 74

8. To remove the verbus-ripp bolts it is necessary to remove the spacer (if installed). Rotate the spacer with a suitable drift to align the holes in the spacer with the space between the bolts.

9. Use two dowels and two heel bars to remove the spacer as shown. Refer to Figure 65.

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00 - General

Figure 65.

J

11.2. Install the four M14 studs and nuts on the annulus carrier. Some annulus carriers have two tapped holes for use with jacking screws. Use two high grade M14 bolts as jacking screws to remove the annulus carrier.

K

Special Tool: Reaction Plate (Qty.: 1) Special Tool: Reaction Plate M14 Studs (Qty.: 4) 11.3. Engage the reaction plate.

AF

11.4. Adjust the studs to maintain a clearance between the reaction plate and the driveshaft.

H

11.5. Install a three leg puller. Engage the puller legs through the holes in the annulus carrier.

H J K AF

11.6. Use the puller to remove the annulus carrier along with the annulus ring from the axle stub shaft.

External circlip 2 Spacer Verbus-ripp bolt Sun gear

11.7. Make sure that the dowels remain either in the annulus carrier or in the stub shaft.

Note: It is normal for fretting to occur on the mating surfaces between the axle stub shaft and annulus carrier. Do not attempt to repair it.

10. Remove the verbus-ripp bolts with a heavy duty socket.

Special Tool: Heavy Duty Socket 19mm A/F x 3/4 in Drive (Qty.: 1) 10.1. Note: the verbus-ripp bolts are very tight and care must be taken not to distort the bolt heads. Use an extension bar as short as possible. Discard the verbus-ripp bolts after removal.

12. Remove the internal circlip to separate the annulus ring from the annulus carrier.

11. Remove the annulus carrier along with the annulus ring as follows: Refer to Figure 66.

13.1. Attach the legs of the bearing puller onto two diametrically opposite wheel studs and put the reaction tube over the driveshaft. Refer to Figure 67.

13. Remove the outer wheel bearing and the bearing carrier as follows:

Figure 66.

Special Tool: Wheel Hub Service Kit (Qty.: 1)

AG AJ

13.3. On five wheel stud axles, the modified wheel studs from the Wheel Hub Service Kit must be used. Bolt to two diametrically opposite holes provided on the bearing carrier.

13.4. Slowly turn the screw until the bearing carrier and the outer wheel bearing are released from the axle stub shaft.

AH AG M14 studs and nuts AH Reaction plate AJ 3 Leg puller

13.5. If the wheel hub starts to rotate use a suitable bar to prevent further rotation.

11.1. Put marks on the stub shaft and annulus carrier to identify their relative angular position during installation.

27 - 75

13.2. The reaction tube must be used otherwise damage to the driveshaft and driveshaft bearings will occur.

9823/0100-1

13.6. If the screw becomes hard to turn, tap the back of the bearing carrier with a soft faced mallet to help release the bearing.

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00 - General

Figure 67.

W

15. Remove the inner wheel bearing as follows: Refer to Figure 69.

Y

Figure 69.

X X Q W X Y

Q

W

Bearing carrier Reaction tube Screw Bar

W Reaction tube X Screw

14. Remove and discard the outer part of the combination oil seal by cutting the outer seal with a sharp chisel. Take care not to damage the seal seat on the axle stub shaft. Refer to Figure 68.

15.1. Clamp the plates around the inner wheel bearing.

15.2. Attach the puller rods and put the reaction tube over the driveshaft.

Figure 68.

15.3. The reaction tube must be used otherwise damage to the driveshaft and driveshaft bearings will occur.

Z

15.4. Slowly turn the screw until the inner wheel bearing is released from the axle stub shaft.

15.5. Remove and discard the inner part of the combination oil seal.

16. If installed do not remove the dirt shield.

T

T Combination oil seal Z Chisel

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00 - General

Figure 70.

M

V

E

D

V

F P

C

L

B

N

H

AF

K

J

G

T

R

U

S A Q A C E G J L N Q S U AF

Screw O-ring Bearing Driveshaft thrust pad Spacer Annulus carrier Internal circlip Bearing carrier Inner wheel bearing Dirt shield (If installed) Sun gear

27 - 77

B D F H K M P R T V

9823/0100-1

Planet gear carrier Planer gear External circlip 1 External circlip 2 Verbus-ripp bolt Annulus ring Dowel Outer wheel bearing Combination oil seal L-shaped circlip

27 - 77

27 - Driveline

27 - Hub

00 - General

Assemble

Figure 73.

AA

1. Install the outer wheel bearing cup into the bearing carrier.

2. Install the inner wheel bearing cup and cone into the bearing carrier.

3. Use the seal dolly 892/00891 from the Wheel Hub Service Kit to install a new combination oil seal. The seal dolly has two sides 'A' and 'B' marked for identification. Do not lubricate the seal before installation. Refer to Figure 71.

B

Figure 71.

Q

A

AA

Q Bearing carrier AA Seal dolly 5. Install the seal on the dolly.

B AA Seal dolly 4. Make sure you use the correct side of the seal dolly as follows:

6. Use a soft-faced mallet to drive the seal squarely into the bearing carrier until the dolly flange is up against the carrier. Refer to Figure 74.

Figure 74.

4.1. For axles with a steel dirt shield use side 'A' of the seal dolly. Refer to Figure 72.

Figure 72.

AA

AA U Q

A

Q Bearing carrier AA Seal dolly 7. Attach the bearing press extension shaft onto the end of the axle stub with four verbus-ripp bolts.

Refer to Figure 75.

Q

Figure 75.

Q Bearing carrier U Dirt shield AA Seal dolly 4.2. For axles without a steel dirt shield use side 'B' of the seal dolly. Refer to Figure 73.

K K Verbus-ripp bolts 27 - 78

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00 - General

8. Lightly apply oil on the inner wheel bearing cone.

22. Install the new verbus-ripp bolts.

9. Position the bearing carrier (complete with inner bearing) onto the axle stub over the extension shaft.

23. Do not tighten the verbus-ripp bolts at this stage.

10. Assemble the bearing press as shown. Refer to Figure 76.

Figure 77.

24. Measure the seal drag rolling force:

Figure 76.

R

BB AC

BA

AD BA Cord BB Spring balance

AB R AB AC AD

24.1. Install the planet gear carrier.

Outer wheel bearing Handle Thrust washers (x2) Reaction tube

24.2. Do not install the sun gear.

24.3. Wrap a cord around the planet gear carrier flange and attach a spring balance to it as shown. Refer to Figure 77.

11. Slide the reaction tube over the extension shaft (the wide opening towards the bearing).

12. Make sure that the bearing and bearing carrier are properly positioned against the axle stub.

24.4. Pull the spring balance so that the hub rotates, do this several times to let the seal bed in and record the reading.

13. Attach the handle and make sure that the thrust bearing is installed between the two thrust washers.

25. Tighten the verbus-ripp bolts to the correct torque value.

14. Slowly turn the handle to press the inner wheel bearing correctly into position, then remove the handle and reaction tube.

24.5. Remove the planet gear carrier.

26. Measure the rolling force:

15. Install the outer wheel bearing cone into the bearing carrier.

16. Assemble the reaction tube and handle onto the extension shaft.

17. Slowly turn the handle to press the outer bearing correctly into position until the free play is removed.

26.1. Install the planet gear carrier.

26.2. Do not install the sun gear.

26.3. Wrap a cord around the planet gear carrier flange and attach a spring balance to it as shown.

26.4. Pull the spring balance so that the hub rotates and record the reading.

18. Remove the handle and reaction tube.

26.5. To calculate the rolling force, subtract the seal drag force (24.4) from the value obtained in the step 26.4.

19. Assemble the annulus ring onto the annulus carrier and then install the internal clip.

26.6. The rolling force should be within the specified range.

20. Make sure that the dowels are correctly installed.

21. Attach the annulus assembly to the axle stub shaft in the same angular position based on the marks made during installation.

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Torque: 2 –22 N¡m 26.7. If the values are outside the limits specified then check if the seal is installed correctly,

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00 - General

30.1. Note: The sun gear must be installed with the 1.5mm x 45° chamfer inboard.

and/or replace the wheel bearings if necessary.

26.8. Remove the planet gear carrier.

27. Press the driveshaft thrust pad (chamfered side faces downwards) into the recess in the planet gear carrier.

28. Install the new planet gears in the position of any that were removed during disassembly. Refer to Figure 77.

28.1. Important: Make sure that you install the planet gears in the correct orientation.

Install the large radius end of the bearing over the pin first. Refer to Figure 78.

31. Install a new O-ring, and then install the planet gear carrier onto the bearing carrier. Make sure that the two tapped holes are in line with those on the bearing carrier.

32. Do not strike the centre of the planet gear carrier during installation as this may dislodge the driveshaft thrust pad.

33. Apply sealant to the threads of the screws. Refer to Figure 80.

Figure 80.

Q

Figure 78.

B

AE A

A Screw AE Large radius end

34. Install the screw to attach the planet gear carrier.

28.2. Secure the planet gears with external circlip 1.

Figure 79.

Item A K

D B

B D G F

36. Fill the hub with the correct grade oil.

Table 28. Torque Values

F G

35. Tighten the screws to the correct torque value.

Nm 56 320

Planet gear carrier Planet gear Driveshaft thrust pad External circlip 1

29. Install the spacer (If installed).

30. Install the sun gear onto the driveshaft and secure with the external circlip 2.

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47 - Propshaft

47 - Propshaft Contents

Page No.

27-47-00 General ........................................................................................................................... 27-83

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Notes:

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27 - Driveline

47 - Propshaft 00 - General

00 - General Introduction ....................................................

Check (Condition) ..........................................

Lubricate ........................................................

Remove and Install .......................................

27 - 83

Introduction 27-83 27-84 27-84 27-85

The propeller shaft or propshaft is usually the shaft that connects the gearbox to the differential or drivehead.

The propshaft is a mechanical component for transmitting torque and rotation, usually used to connect components of a drivetrain that cannot be connected directly because of distance or the need to allow for relative movement between them.

9823/0100-1

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27 - Driveline

47 - Propshaft 00 - General

Check (Condition)

Lubricate

1. Make the machine safe. Refer to (PIL 01-03).

1. Make the machine safe. Refer to (PIL 01-03).

2. Check the propshaft tube for damage or cracks.

2. Make sure you have the correct grease.

3. Check the centre bearing (if installed) for security, cracks or damage.

4. Check the universal joints for security, cracks or damage. Make sure that there is no play in the joint and that grease points are present (if installed).

Refer to: PIL 75-00-00.

3. Use a grease gun to lubricate the universal joint grease points until fresh grease appears past the seals of all four bearings in each joint.

3.1. If grease does not appear, push the propshaft away from the bearing that grease does not appear from and grease again.

5. Check the sliding joints for security, cracks or damage. Make sure that there is no play in the joint and that grease points are present (if installed).

6. Check any sensor or sensor ring for security, cracks or damage (if installed).

7. Make sure the correct fasteners are installed and tightened to the correct torque.

3.2. If grease still does not appear, remove and examine the bearing. Renew if necessary.

Refer to: PIL 27-47-00.

4. Remove any excess grease.

8. Renew any defective component as needed.

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47 - Propshaft 00 - General

Remove and Install

Install

Consumables Description JCB Threadlocker and Sealer (Medium Strength) Special MPL-EP Grease

1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps.

Part No. 4101/0250 4101/0251

Size 0.01 L 0.05 L

4003/1501 4003/1506 4003/1510

0.4 kg 12.5 kg 50 kg

Before you remove the propshaft, always mark on both companion flanges and also mark the sliding joints to help correct alignment when you install.

Remove 1. Make the machine safe. Refer to (PIL 01-03).

2. Put chocks against the all four wheels.

2. Lubricate the sliding joints with specified grease and then align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturer's alignment markings.

Consumable: Special MPL-EP Grease 3. The retaining straps stretch with use, therefore these straps must always be replaced with new ones.

4. For Synchro shuttle machines, apply JCB Threadlocker and Sealer to threads of all flange bolts.

Consumable: JCB Threadlocker and Sealer (Medium Strength)

3. Remove the strap bolts and straps.

4. Remove the flange bolts and remove the propshaft from the machine.

5. The propshaft must have both ends exactly on the same plane. The yokes must not be at right angles or at an intermediate angle.

Figure 81.

Figure 82.

X

C

Y

B A

Z

A Bolts B Strap C Flange bolts 27 - 85

X Correct installation - yokes correctly aligned on the same plane Y Incorrect installation - yokes at right angles to each other Z Incorrect installation - yokes at intermediate angles to each other 6. Tighten the bolts to the correct torque value.

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47 - Propshaft 00 - General

Table 29. Torque Values Item A C

27 - 86

Nm 75–85 118

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27 - Driveline 51 - Driveshaft

51 - Driveshaft Contents

Page No.

27-51-00 General ........................................................................................................................... 27-89 27-51-15 Shaft Hub Side ............................................................................................................... 27-93

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Notes:

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27 - Driveline 51 - Driveshaft

00 - General

00 - General

Introduction

Introduction .................................................... 27-89 Component Identification ............................... 27-90 Disassemble and Assemble .......................... 27-92

The driveshaft is a mechanical component for transmitting torque and rotation, usually used to connect other components of the driveline that cannot be connected directly because of distance or the need to allow for relative movement between them.

27 - 89

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27 - Driveline 51 - Driveshaft

00 - General

Component Identification Main Component Identification Figure 83.

1

2

3

4

5

6 7

Table 30.

Item 1 2 3

27 - 90

Description Hub swivel Trunnion (upper) Bearing (taper roller)

Item 4 5 6 7

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Description Axle arm Driveshaft Bearing (taper roller) Trunnion (lower)

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27 - Driveline 51 - Driveshaft

00 - General

Sectional Drawing Figure 84.

1

2

3

4

5

6

5

7

8

9

Table 31.

Item 1 2 3 4 5 6 7 8 9 27 - 91

Description Bearing (needle roller) Circlip (internal) Oil seal Spacer Grease nipple Seal Trunnion Bearing (taper roller) Retaining bolt 9823/0100-1

27 - 91

27 - Driveline 51 - Driveshaft

00 - General

Disassemble and Assemble Refer to Front Driveshaft, Shaft Hub Side (PIL 27-51-15).

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27 - Driveline 51 - Driveshaft

15 - Shaft Hub Side

15 - Shaft Hub Side

Calibrate

Calibrate ........................................................ 27-93 Disassemble and Assemble .......................... 27-95

Consumables Description JCB Threadlocker and Sealer (Medium Strength)

Part No. 4101/0250 4101/0251

Size 0.01 L 0.05 L

Calibrate Previous axles had a shim installed under the top trunnion. The shim controls the bearing pre-load.

When you assemble, select the correct thickness shim and check the bearing pre-load as follows: 1. Locate the hub swivel and install the bottom trunnion.

2. Apply JCB Threadlocker to the bottom trunnion bolts.

Consumable: JCB Threadlocker and Sealer (Medium Strength) 3. Tighten the bolts to the specified torque value.

Torque: 98 N¡m 4. Install the top trunnion and finger tighten the top trunnion bolts.

5. Attach a spring balance to the track rod swivel and note the reading. Refer to Figure 85.

Figure 85. Measuring the swivel turning force

6. Tighten the top trunnion bolts to stop end float but not the bearing pre-load, so that there is no increase in the spring balance reading.

7. Measure the gap at the top trunnion and subtract 1 mm (0.040 in) to give the shim thickness (bearing pre-load). Refer to Figure 86.

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27 - Driveline 51 - Driveshaft

15 - Shaft Hub Side

Figure 86. Measuring the top trunnion gap

8. Remove the top trunnion and install the correct shim.

9. Install the top trunnion.

10. Apply JCB Threadlocker to the top trunnion bolts.

Consumable: JCB Threadlocker and Sealer (Medium Strength) 11. Tighten the bolts to the specified torque value.

Torque: 98 N¡m 12. Check that the spring balance reading which should be 4.5 kgf (10lbf) more than the reading mentioned in the step 5.

Table 32. Example of shim thickness calculation Gap Subtract Shim Thickness

27 - 94

1.55 mm 1 mm 0.55 mm

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27 - Driveline 51 - Driveshaft

15 - Shaft Hub Side

Disassemble and Assemble Special Tools Description Impulse Extractor Bearing Removal Tool Adaptor Consumables Description JCB Threadlocker and Sealer (Medium Strength) Special HP Grease

3. Mark the position of the top and bottom trunnions.

Remove the bolts and remove the trunnions.

Part No. 892/00224 892/00225 993/59500

Qty. 1 1 1

Part No. 4101/0250 4101/0251

Size 0.01 L 0.05 L

4003/2020 4003/2017 4003/2006 4003/2005

0.5 kg 0.4 kg 12.5 kg 50 kg

4. Remove the hub swivel.

5. To easily remove the trunnions, pump grease through the grease nipple.

The hub assembly must be removed before you attempt to remove the hub swivel and driveshaft.

Refer to the applicable axle hub removal procedure.

1. Disconnect the track rod and steering cylinder from the axle steer knuckles.

27 - 95

6. If it is necessary to replace, remove the top and bottom trunnion oil seals and bearings.

7. Use an adaptor with a slide hammer tool to remove the driveshaft oil seal1 and the needle roller bearing from the hub swivel.

Special Tool: Impulse Extractor (Qty.: 1) Special Tool: Adaptor (Qty.: 1) 8. Remove the driveshaft from the axle.

Disassembly

2. The top and bottom trunnions are the same.

Consumable: Special HP Grease

9. Prise out the driveshaft oil seal 2 from the axle ram.

10. Use a tool (892/00225) to remove the drive shaft inner bearing.

Special Tool: Bearing Removal Tool (Qty.: 1) 11. If there has been a component failure, remove all traces of debris from the axle and clean the magnetic drain plug.

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27 - Driveline 51 - Driveshaft

15 - Shaft Hub Side

Figure 87.

20 23 25 27 30 32

Trunnions Hub swivel Bearing Drive shaft seal Driveshaft inner oil seal Driveshaft inner bearing

27 - 96

21 24 26 28 31

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Trunnion bolts Trunnions seals Driveshaft Needle roller bearing Circlip

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27 - Driveline 51 - Driveshaft

15 - Shaft Hub Side

Assembly 1. Tap the driveshaft inner bearing into the position in the axle case.

2. Install a new driveshaft oil seal 2. Apply grease between the lips of the seal.

19. Connect the track rod and steering cylinder to the axle steer knuckles.

Table 33. Torque Values Item 21

Description Trunnion bolts

Nm 98

Consumable: Special HP Grease 3. Tap the driveshaft needle roller bearing into the position in the hub swivel driveshaft bore.

4. Install new driveshaft oil seal 1. Apply grease between the lips of the seal.

Consumable: Special HP Grease 5. Instal the spacer.

6. Install the driveshaft. Carefully locate the end into the splines of the differential gears.

7. Push the new trunnion oil seals into the position followed by the bearings.

8. Apply grease on the bearing and the oil seal before you install them to the axle.

Consumable: Special HP Grease 9. In the following step, take care not to damage the trunnion oil seals when you tighten the trunnion bolts.

10. Previous axles have a shim installed under the top trunnion. Where a shim is installed follow the calibration procedure.

11. Locate the hub swivel and install the top and bottom trunnions.

12. Apply JCB Threadlocker to threads of trunnion bolts.

Consumable: JCB Threadlocker and Sealer (Medium Strength) 13. First finger tighten all of the bolts then sequentially tighten them to bring the two trunnions together.

14. Tighten the bolts to the correct torque value.

15. Make sure that the swivel rotates smoothly on its trunnions.

16. Stiff movement may result if seals have become displaced and damaged during assembly.

17. Make sure that the grease nipple is clear and not damaged, replace as necessary.

18. Tighten the nipple to the specified torque value.

Torque: 56 N¡m

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Notes:

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30 - Hydraulic System Contents

Page No.

30-15 Cylinder / Ram 30-15-00 General ............................................................................................................................. 30-3 30-15-34 Steering ............................................................................................................................ 30-7 30-15-99 Seal Kit ........................................................................................................................... 30-17

9823/0100-1 2017-07-18

Notes:

9823/0100-1 2017-07-18

30 - Hydraulic System

15 - Cylinder / Ram

15 - Cylinder / Ram Contents

Page No.

30-15-00 General ............................................................................................................................. 30-3 30-15-34 Steering ............................................................................................................................ 30-7 30-15-99 Seal Kit ........................................................................................................................... 30-17

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30 - 1

Notes:

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9823/0100-1

30 - 2

30 - Hydraulic System

15 - Cylinder / Ram 00 - General

00 - General Introduction ......................................................

Health and Safety ...........................................

Check (Condition) ............................................

Check (Operation) ...........................................

Introduction 30-3 30-4 30-5 30-6

A hydraulic cylinder ram is a mechanical actuator that is used to give a single directional force through a single action stroke. It is used in many applications, the cylinder gets the power from pressurised hydraulic oil. The hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a piston rod moves back and forth.

The barrel is closed on one end by the cylinder cap and the other end by the cylinder head where the piston rod comes out of the cylinder. The piston has sliding rings and seals. The piston divides the inside of the cylinder into two chambers, the bottom chamber (cap end) and the piston rod side chamber (rod end / head end).

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30 - Hydraulic System

15 - Cylinder / Ram 00 - General

Health and Safety

Caution During Use 1. Use only under designated conditions.

Hydraulic Pressure

1.1. If hydraulic oil other than the designated oil is used, the seals quickly degenerate and become damaged. If the relief valve is set at a value higher than specified, it may cause ram damage and is dangerous.

Hydraulic fluid at system pressure can injure you.

Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.

1.2. In high temperature environments (approx.

90°C and above) or low temperature environments (below -20°C), seals quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or not.

Lifting Equipment You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.

WARNING! A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the machine being started while you are beneath it.

1.3. The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.

2. Warm up sufficiently before beginning work.

2.1. In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the seals will be damaged.

2.2. There is a large amount of air in a new ram or one which has been left for a long time, so the ram will not operate smoothly.

Also, if pressure is applied suddenly without bleeding the air, high temperatures will be generated due to adiabatic compression and the seals may burn.

Precautions for Installation 1. Precautions when installing the ram on the machine.

1.1. When installing and removing from the machine, suspend the ram safely.

1.2. Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder.

1.3. Secure the piston rod with a band. It is very dangerous if the rod extends unexpectedly.

Also, the rod can be damaged and become unusable.

2.3. Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder.

3. When stopping or storing, do it at a safe and fixed position.

3.1. The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools.

Stop or store the machine in a safe and fixed position.

2. Welding after installing the ram may result in damage.

2.1. If electric welding is done even at a point away from the ram, there may be sparking inside the ram and it will become necessary to replace the ram with a new one.

Maintenance, Inspection Points 1. Carry out daily maintenance and inspection.

3. When painting the machine, mask the ram. If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly and foreign matter and paint can easily enter the ram. This will cause damage to the seals, drastically shortening the life of the ram.

4. Install the ram only when it is clean.

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9823/0100-1

1.1. The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and inspection so that the ram functions fully at all times. Always remove any mud, water, dust or oil film adhering to the rod and keep it in normal condition. However, when cleaning the wiper ring and seals, do not get them wet with water but wipe clean with a rag. To prevent rust forming during storage, the amount of exposed ram piston rod 30 - 4

30 - Hydraulic System

15 - Cylinder / Ram 00 - General

should be kept to a minimum. If leaving for more than one week, apply a light coating of suitable grease or petroleum jelly to the exposed part of the ram piston rod.

2. Use genuine JCB parts when replacing parts.

2.1. If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts.

Check (Condition) Maintenance and Inspection 1. Always do the daily maintenance and inspection of the hydraulic rams.

1.1. The key point for the correct long term ram function is daily maintenance and inspection. Do the maintenance and inspection to operate the rams satisfactorily.

3. Caution during dismantling and reassembly.

3.1. Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine can occur. Remove the ram from the machine and then dismantle.

1.2. Always remove any mud, water, dust or oil film adhering to the rod and keep the ram in normal condition.

1.3. Do not use water when you clean the wiper ring and seals, use a rag to clean.

3.2. If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic equipment may be damaged. Reassemble in a clean state.

1.4. To prevent rust formation during the machine storage on the ram piston rod, the amount of exposed time must be kept to a minimum.

1.5. When you put the machine into storage for more than one week, apply a light coat of suitable grease or petroleum jelly to the exposed part of the ram piston rod.

3.3. Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low, it can cause damage.

2. Make sure that the genuine JCB parts are used when you replace the parts.

2.1. If you used parts other than genuine JCB parts, the desired results may not be obtained. JCB recommend you to use only genuine JCB parts.

3. Take care when you disassemble and assemble the hydraulic ram.

3.1. If you disassemble the ram on the machine, it may be dangerous as possible movements of the ram may occur.

3.2. If you do not obey the cleanliness procedures during the ram assembling, foreign matter may enter the ram, and damage to the ram and other hydraulic equipments.

3.3. Always obey the cleanliness procedures when you assemble the hydraulic ram.

3.4. Always obey the correct torque tightening instructions regarding the screwed parts for the ram. If the torque value is applied too high or too low, it may cause damage.

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15 - Cylinder / Ram 00 - General

Check (Operation) Operation 1. The hydraulic ram should only be operated under the designated conditions.

1.1. If you use oil other than the recommended hydraulic oil, the seals can quickly degenerate and become damaged.

1.2. If the relief valve is set at a value higher than the recommended, it may cause ram damage and it is dangerous.

1.3. In the higher (approximately 90°C and above) or lower (below -20°C) temperature work environments, the seals quickly become damaged.

1.4. To get the desired operation of the ram in these work environment, the seals are made from special materials.

1.5. The basic cause of ram oil leakage is rod damage.

1.6. Be careful when you handle the ram rod which must not be damaged.

2. Operate the engine at idle speed to get the desired normal temperature of the hydraulic oil, before you start the ram operation.

2.1. In cold conditions the rod seals may be frozen, and if you operate the ram at maximum pressure and speed, the seals will be damaged.

2.2. A new ram has a large amount of trapped air which may have been left for a long time, if you operate such a ram, it will not operate smoothly. If you apply pressure suddenly without bleeding the air from the ram, high temperatures will be generated and the seals will burn.

2.3. Before you operate the ram, always move the ram at full stroke with no load and bleed air from the ram cylinder.

3. When you stop the ram operation, do it at a safe and fixed position.

3.1. The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak and the hydraulic oil volume decreases as it cools.

Keep the machine in a safe and fixed position.

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

34 - Steering

Component Identification

Component Identification ................................. 30-7 Bleed ............................................................. 30-10 Remove and Install ....................................... 30-10 Disassemble and Assemble .......................... 30-12

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

Figure 88.

1 13 7 3

6

5

11

10

9

4

8

12

2

1 3 5 7 9

End cap Lock ring Seal Piston head O-ring

30 - 8

2 4 6 8 10 9823/0100-1

Piston rod assembly Wear ring 1 Wear ring 2 Seal Seal 30 - 8

30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

11 13

Seal Bearing bush - rod eye end

30 - 9

12

9823/0100-1

Bearing bush - rod eye end

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

Remove and Install

Bleed Whenever any hydraulic steering component is disconnected or removed from the system, you must be bleed as follows: With the engine running, follow this procedure in the order shown, you must not alter the order of selections and operations.

1. Select 2 Wheel Steer.

1.1. Turn steering wheel to left, until front wheels are fully locked to the left.

1.2. Turn steering wheel to right, until front wheels are fully locked to the right.

2. Select 4 Wheel Steer.

2.1. Turn steering wheel to left, until front wheels are fully locked to the left.

3. Select 2 Wheel Steer.

3.1. Turn steering wheel to full right lock.

WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end.

Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

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

Removal and Install The axle may be installed with either a single or twin cylinder system.

Removal 1. Make the machine safe.

Refer to: PIL 01-03.

2. Disconnect and cap all the hydraulic hoses to prevent loss of fluid and ingress of dirt.

3.2. Turn steering wheel to full left lock.

3. Make sure to label or mark the hoses for identification and correct installation.

3.3. Turn steering wheel to full right lock.

4. Remove the locking bolts and pivot pins.

4. Select 4 Wheel Steer.

5. Remove the steering cylinders from the machine.

4.1. Turn steering wheel to left, until the front wheels are fully locked to the left.

5. Select 2 Wheel Steer.

5.1. Turn steering wheel to fully right lock.

5.2. Turn steering wheel to fully left lock.

5.3. Turn steering wheel to fully right lock.

6. Select 4 Wheel Steer.

6.1. Turn steering wheel to left, until front wheels are fully locked to the left.

7. Select 2 Wheel Steer.

7.1. Turn steering wheel to full right lock.

7.2. Turn steering wheel to full left lock.

7.3. Turn steering wheel to full right lock.

8. Select 4 Wheel Steer.

8.1. Turn steering wheel to left, until the front and rear wheels are fully locked.

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

Figure 89.

D

C

B

A B

A B C D

Bolt Pivot pin Pin Ring

Install 1. The installation procedure is the opposite of the removal procedure. Additionally do the following steps.

2. Apply anti-seize paste to the pivot pins, to facilitate subsequent removal.

3. After connecting the hoses, check the hydraulic fluid level.

3.1. If necessary, top up as required.

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

Disassemble and Assemble Special Tools Description Temperature Probe Ram Piston Nut Removal Installation Spanner 55mm A/F Ram Piston Nut Removal Installation Spanner 60mm A/F Ram Piston Nut Removal Installation Spanner 65mm A/F Ram Piston Nut Removal Installation Spanner 70mm A/F Ram Piston Nut Removal Installation Spanner 80mm A/F Ram Piston Nut Removal Installation Spanner 95mm A/F Consumables Description Cleaner/Degreaser - General purpose solvent based parts cleaner Special HP Grease

1. Make the machine safe.

Part No. 892/00285 993/99512

Qty. 1 1

993/99513

1

993/99514

1

993/99515

1

SSP0046

1

SSP0047

1

Part No. 4104/1557

Size 0.4 L

4003/2020 4003/2017 4003/2006 4003/2005

0.5 kg 0.4 kg 12.5 kg 50 kg

Refer to: PIL 01-03.

2. Disassemble the cylinder ram in the numerical sequence.

3. Put the cylinder assembly on a clean workbench.

4. Use the special spanner to loosen the end cap assembly and remove the piston rod assembly from the cylinder.

Special Tool: Ram Piston Nut Removal Installation Spanner 55mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 60mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 65mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 70mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 80mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 95mm A/F (Qty.: 1) 5. Position the piston rod assembly on bench in place of cylinder.

6. Remove the seal and wear rings from the piston head.

7. Remove the locking ring.

8. Heat the piston head (180-210 °C) to degrade the Loctite between piston head and rod.

8.1. Use the surface temperature probe to check the temperature.

Disassemble and Assemble (without Dowel) CAUTION If air or hydraulic pressure is used to force out the piston assembly, ensure that the end cap is securely installed. Severe injury can be caused by a suddenly released piston rod.

CAUTION To avoid burning, wear personal protective equipment when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.

Special Tool: Temperature Probe (Qty.: 1) 8.2. Do not exceed 300 °C or the Loctite will char, causing thread pick-up.

9. Use special spanner to remove the piston head from rod.

10. Remove end cap from the piston rod and remove the seals and O-ring.

11. Make sure that the metal components are free from scoring, nicks and burrs.

Disassemble Refer to Figure 90.

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

Figure 90.

1 13 7 3

6

5

11

10

9

4

8

12

2

1 3 5 7 9

End cap Lock ring Seal Piston head O-ring

30 - 13

2 4 6 8 10 9823/0100-1

Piston rod assembly Wear ring 1 Wear ring 2 Seal Seal 30 - 13

30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

11 13

12

Seal Bearing bush - rod eye end 11.1. A damaged rod will impair the life of the gland seal.

Assemble 1. Use a wire brush and clean the threads of piston rod, piston head, end cap and cylinder.

2. Use cleaner/ degreaser to make sure that all the threads are free from grease, hydraulic oil and old Loctite.

Consumable: Cleaner/Degreaser purpose solvent based parts cleaner

General

2.1. Allow 15 minutes for the solvent to dry before applying Loctite.

3. Make sure that all lubricants used during assembly, do not come into contact with Loctite.

4. Install the seals into the end cap, then install the end cap into the piston rod. Refer to Seal Installation procedure.

10. When operating in cold weather conditions, which is consistently below freezing. It is recommended that the cylinders are operated slowly to their full extent before commencing normal working.

Disassemble and Assemble Dowelled Piston Head) Refer to Figure 90.

1. Make the machine safe.

Refer to: PIL 01-03.

2. Put the cylinder assembly on a clean workbench.

3. Use the special spanner to loosen the end cap assembly and remove the piston rod assembly from the cylinder.

Special Tool: Ram Piston Nut Removal Installation Spanner 55mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 60mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 65mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 70mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 80mm A/F (Qty.: 1) Special Tool: Ram Piston Nut Removal Installation Spanner 95mm A/F (Qty.: 1)

5. Apply Loctite Activator to threads of piston rod, end cap and cylinder. All Activator to dry for 15 minutes before bringing into contact with Loctite.

5.1. Make sure that the Loctite or Activator are not allowed to contact seals, bearing rings or o-rings.

Consumable: Special HP Grease 7. Install a new seal and wear rings to piston head.

8. Position the cylinder on a clean workbench and install the rod assembly into the cylinder.

9. Apply Loctite 932 to thread of end cap, install a new O-ring and tighten torque the end cap into the cylinder.

9.1. If hydraulic cylinder contacts uncured Loctite a weakening of the bond will result.

Cure times vary according to the ambient temperature and type of Activator used. The following approximate cure time applies at 20 °C and is the minimum period between the assembly and filling the cylinder with oil.

9.2. Loctite 262 or 932 with Activator - 1 hour.

30 - 14

(with

Disassemble

Refer to: PIL 30-15-99.

6. Apply Loctite 262 to all threads of piston rod.

Install O-ring in piston head, lubricating only the O-ring with Mobil HP222 grease. Install and tighten the piston head to the correct torque value. Install a new locking ring.

Bearing bush - rod eye end

4. Position the piston rod assembly on the workbench in place of the cylinder.

5. Extract the dowel from the piston head, using a metric screw threaded into the extractor hole.

6. Use special spanner to remove the piston head from rod.

7. Remove gland bearings and end cap from piston rod and remove seals and back-up rings. Refer to Seal Installation procedure.

Refer to: PIL 30-15-99.

7.1. Make sure that the metal components are free from scoring, nicks and burrs.

7.2. A damaged rod will impair the life of the gland seal.

Assemble 1. Use a wire brush and clean the threads of piston rod, piston head, end cap and cylinder.

9823/0100-1

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

2. Use cleaner/ degreaser to make sure that all the threads are free from grease, hydraulic oil and old Loctite.

Consumable: Cleaner/Degreaser purpose solvent based parts cleaner

4. New piston head installed on a pre-drilled piston rod.

4.1. Drill and dowel both the piston head and piston rod at 90 °C from the existing drilled dowel hole in the piston rod. Follow the above procedures at step 3.

General

2.1. Allow 15 minutes for the solvent to dry before applying Loctite.

3. Make sure that all lubricants used during assembly, do not come into contact with Loctite.

5. New piston rod installed to a pre-drilled piston head. Refer to Table 34.

5.1. Use the pre-drilled in the piston head. Care must be taken not to elongate the existing hole in the piston head.

4. Install seal into end cap first, followed by circlip.

Insert seal and back-up ring into the end cap.

Refer to Seal Installation procedure.

5.2. Use a drill the same diameter as the predrilled hole in the piston head to make a 'centre mark' in the piston rod. Do not drill the piston rod at this stage.

Refer to: PIL 30-15-99.

4.1. Install the external O-ring.

5.3. Use an undersized diameter drill as a guide and drill into the piston rod to the required depth. make sure the drill has centred correctly on the center mark.

5. Use sleeve, overleaf, installed over piston rod threads to protect the seals from damage and the threads from oil and grease. Install the gland bearing into the end cap and push the assembly over the sleeve onto the rod.

5.4. Use the correct side diameter drill to suit the dowel and drill to the required depth.

6. Apply Loctite Activator to threads of end cap and cylinder. Allow the Activator to dry for 15 minutes before bringing into contact with Loctite.

5.5. Remove all swarf and contamination, insert the dowel.

7. Do not allow the Loctite or Activator to contact the seals, bearing rings or O-rings.

6. Position cylinder on workbench and install rod assembly into cylinder.

Installation of Locking Dowel to Piston head/rod as follows:

7. Apply Loctite 932 to first three threads of cylinder, tighten the end cap to the correct torque value.

7.1. If hydraulic oil contacts uncured Loctite a weakening of the bond will result.

Cure times vary according to the ambient temperature and type of Activator used. The following approximate sure times apply at 20 and are the minimum periods between assembly and filling the cylinder with oil.

1. Install O-ring into piston head.

2. Install the piston head to piston rod and tighten to the correct torque value.

3. New cylinder shaft and piston head installed.

3.1. If both are required, the following procedure should be followed: 3.2. Drill though piston head into piston rod. Use an undersized diameter drill first as a guide and then drill with the correct size diameter drill to suit.

3.3. Remove all swarf and contamination. Insert the dowel into drilled hole, make sure tapped extractor hole is to the outside.

7.2. Loctite 262 or 932 with Activator - 1 hour.

8. When operating in cold weather conditions, which is consistently below freezing. It is recommended that the cylinders are operated slowly to their full extent before commencing normal working.

Table 34. Drilling Details for Piston Head Retention (all diameters in mm) Cylinder Size

Dowel Size

Guide Drill

90 x 50 100 x 60 110 x 60 110 x 65

80 x 25 120 x 30

30 - 15

Dowel Drill

5

Guide Drill Depth 24

8.02/8.10

Dowel Drill Depth 27/28

8

28

12.02/12.10

32/33

9823/0100-1

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30 - Hydraulic System

15 - Cylinder / Ram 34 - Steering

Cylinder Size

Dowel Size

Guide Drill

120 x 65 130 x 75

120 x 35

8

Guide Drill Depth 33

Dowel Drill 12.02/12.10

Dowel Drill Depth 37/38

Table 35. Torque Values Item 1 7

30 - 16

Description End cap Piston head

Nm 678 405

9823/0100-1

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30 - Hydraulic System

15 - Cylinder / Ram 99 - Seal Kit

99 - Seal Kit

Figure 91.

Remove and Install Special Tools Description Ram Protection Sleeve (90mm rod diameter) Ram Seal Installation Tool Ram Protection Sleeve (25mm rod diameter) Ram Protection Sleeve (30mm rod diameter) Ram Protection Sleeve (40mm rod diameter) Ram Protection Sleeve (50mm rod diameter) Ram Protection Sleeve - Slew (50mm rod diameter) Ram Protection Sleeve (60mm rod diameter) Ram Protection Sleeve - Slew (60mm rod diameter) Ram Protection Sleeve (65mm rod diameter) Ram Protection Sleeve (70mm rod diameter) Ram Protection Sleeve (75mm rod diameter) Ram Protection Sleeve (80mm rod diameter) Ram Seal Assembly Tool

Part No. 892/00167

Qty. 1

892/00334

1

892/01016

1

892/01017

1

892/01018

1

892/01019

1

892/01020

1

892/01021

1

892/01022

1

892/01023

1

892/01024

1

892/01025

1

892/01026

1

892/01027

1

A Ram seal installation tool B Pins 1.2. Open the seal installation tool and insert the new rod seal. Install the seal behind the two front pins but in front of the rear pin as shown.

Figure 92.

A Rod seal 1.3. Later ram end caps and piston heads have metric threads. The seals are also different, make sure that the correct seals are installed. On metric threaded rams, make sure that the seals are installed the correct way around, as shown.

Figure 93.

Remove 1. Remove and discard the old seals.

Refer to: PIL 30-15-00.

Install 1. Install new rod seals: 1.1. Use the ram seal installation tool to install rod seals, the size (diameter) and position of pins is determined by the diameter and radial width of the rod seal being installed.

The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals.

A Inner seal B Outer seal 1.4. Close the tool. The seal must form a reniform (kidney shape).

Special Tool: Ram Seal Installation Tool (Qty.: 1) 30 - 17

9823/0100-1

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30 - Hydraulic System

15 - Cylinder / Ram 99 - Seal Kit

Figure 94.

Special Tool: Ram Protection Sleeve - Slew (60mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (65mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (70mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (75mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (80mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (90mm rod diameter) (Qty.: 1)

1.5. Before you install the rod seals, check that the seal grooves are free of contamination and sharp edges.

Figure 96.

1.6. Locate the seal in the end cap groove.

When the seal is in position, open the tool to release the seal. Make sure the seal is correctly installed in its grooved and remove the tool.

Figure 95.

A Protection Sleeve (various sizes) 2. Install new head piston seals.

1.7. Install the rod wiper seal into the seal groove. Make sure that the seal is correctly installed as shown. Note: Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to make sure that the seal is square before it is pressed in.

2.1. Use the Piston seal assembly tool to lever the inner seal into the piston head seal groove. Do not let the seal twist. There are identification marks on the outer diameter of the seal, make sure that the marks are visible and the seal is free to rotate, if not remove the seal and retry.

Special Tool: Ram Seal Assembly Tool (Qty.: 1) Figure 97.

1.8. A special sleeve must be used to protect the rod seals from damage, when installing the end cap on to the piston rod. There are various sizes of sleeve, make sure you use the correct size sleeve and also make sure that the hexagon on the end cap is towards the eye end of the rod.

Special Tool: Ram Protection Sleeve (25mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (30mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (40mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (50mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve - Slew (50mm rod diameter) (Qty.: 1) Special Tool: Ram Protection Sleeve (60mm rod diameter) (Qty.: 1) 30 - 18

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A Piston seal assembly tool B Inner seal C Outer seal

30 - 18

30 - Hydraulic System

15 - Cylinder / Ram 99 - Seal Kit

2.2. Use the same procedure to install the outer seal as stated for the inner seal. Check that the external grooves are visible.

2.3. Make sure that the O-ring is installed into the internal seal groove on the piston head.

Screw the piston head on to the thread of the piston rod and tighten to the correct torque value.

Refer to: PIL 30-15-00.

2.4. Install the piston head retaining dowel.

Refer to: PIL 30-15-00.

2.5. Install wear rings, rotate the wear rings so that the piston retention dowel is covered by the wear ring, not as shown at C. Figure 98.

A Outer wear ring B Inner wear ring C Incorrect installation 3. Install the piston rod and head assembly into the cylinder.

3.1. Insert the piston/rod assembly into the cylinder ram. Align the rod and head assembly until parallel with the cylinder ram then push the assembly into the cylinder.

3.2. Install the end cap and assemble the ram assembly.

Refer to: PIL 30-15-00.

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Page No.

72-00 Fasteners and Fixings 72-00-00 General ............................................................................................................................. 72-3 72-03 Screws 72-03-00 General ............................................................................................................................. 72-7 72-06 Bolts 72-06-00 General ........................................................................................................................... 72-11

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Notes:

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00 - Fasteners and Fixings 00 - General

00 - General

Fastener Type Colour

Introduction

Zinc Nickel black Zinc flake black

JCB Fasteners (Before September 2017) Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines. The two types of fasteners can be readily identified by colour and part number suffix. Refer to Table 1. Fastener Types.

Table 36.

Fastener Type Colour Zinc and Yellow Golden Finish Dacromet

Mottled Silver Finish

Torque and Angle Tightening Insufficient pre-load of a bolted joint can cause major problems, such as cylinder head warp, leaking gasket joints etc. There are several methods of achieving an accurate pre-load of a bolted joint, the two main methods used on the JCB engine are: •

Part Number Suffix Z (e.g.

1315/3712Z) D (e.g.

1315/3712D)

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.

•

A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

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

Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

JCB Fasteners (After September 2017) Table 37.

Fastener Type Colour

Part Number Suffix D (e.g.

1315/3712D)

Zinc flake-silver White aluminium (silver-grey), Dull Zinc and heavy Silver (Bright iri- V (e.g. trivalent passi- descent) 1315/3712V) vated with seal Zinc Nickel - sil- Dark, dull silver Not assigned ver/grey grey 72 - 3

Black, chalky texture Black, slight gloss

Part Number Suffix N (e.g.

1315/3712N) B (e.g.

1315/3712B)

Torque Control Tightening - Using a torque meter to control the torque is the most popular means of controlling pre-load, and in the majority of instances this method is adequate. It should be noted that with this process, the majority of the torque is used to overcome friction, therefore slight variations in the frictional conditions can lead to large changes in the bolt pre-load.

Angle Control Tightening - Where a more precise pre-load is required, the torque and angle tightening method is used. The bolt is tightened to a predetermined torque (this may be done in stages), and then as a final sequence, the bolt is tightened to a predetermined angle - this method of tightening the bolts results in a smaller variation in the final pre-load. It is critical that the predetermined tightening angle is accurately achieved, failure to tighten accurately to the specified angle could result in the bolt pre-load being incorrect - this will lead to eventual failures. It is good practice to replace all bolts that have been tightened using the torque + angle procedure.

Tightening Method The following example explains the recommended torque and angle procedure. A torque angle gauge should be used for accuracy, but as a visual check, the bolts can be match marked as described below.

1. Tighten the bolt to the specified torque (specified torque values will be detailed in the relevant PIL sections).

2. Mark a line across the centre of the bolt, and a second line on the part to be clamped - the two lines should be aligned. Refer to Figure 99.

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72 - Fasteners and Fixings

00 - Fasteners and Fixings 00 - General

Figure 99.

0°

3. Mark a third line at the specified torque angle - in this instance the additional torque angle is 90°.

This line must be marked the specified angle in a clockwise direction (to further tighten the bolt).

Refer to Figure 100.

Figure 100.

+90°

4. In some instances, angle torque tightening can be specified in two stages, for instance in this example, the first angle quoted is 90° and then a second angle of 180°. The additional 180° angle is from the LAST tightened position. Refer to Figure 101.

Figure 101.

+180°

+90°

5. Tighten the bolt so that the line on the bolt aligns with the angle(s) marked on the item to be clamped - remember, to ensure complete accuracy an angle gauge should be used.

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03 - Screws

03 - Screws Contents

Page No.

72-03-00 General ............................................................................................................................. 72-7

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03 - Screws 00 - General

00 - General

Introduction

Introduction ...................................................... 72-7 Technical Data ................................................. 72-8

Use the torque setting tables (Technical Data) only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. Torque settings are given for the following conditions: Table 38. Up to September 2017 Type no coating 2 (obsolete from September 2017).

3, 4 (obsolete from September 2017).

Condition 1 Condition 2 Unlubricated fas- Zinc flake silver teners (Dacromet) fasteners.

Zinc fasteners Lubricated zinc and yellow plated fasteners.

Yellow plated fas- Where there is teners a natural lubrication. For example, cast iron components.

Table 39. From September 2017 Type no coating 1 5 7 8 9

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Condition 1 Unlubricated fasteners Zinc flake - silver Zinc and heavy trivalent with seal Zinc nickel - silver Zinc nickel - black Zinc flake - black

Condition 2 Dacromet) fasteners.

Zinc flake silver (Dacromet) fasteners.

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72 - Fasteners and Fixings

03 - Screws 00 - General

Technical Data Table 40. Torque Settings - Internal Hexagon Headed Capscrews (Zinc) Bolt Size mm 3 4 5 6 8 10 12 16 18 20 24

72 - 8

N·m 2 6 11 19 46 91 159 395 550 770 1,332

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06 - Bolts Contents

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72-06-00 General ........................................................................................................................... 72-11

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72 - Fasteners and Fixings 06 - Bolts

00 - General

00 - General

Introduction

Introduction .................................................... 72-11 Technical Data ............................................... 72-12

Use the torque setting tables (Technical Data) only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. Torque settings are given for the following conditions: Table 41. Up to September 2017 Type no coating 2 (obsolete from September 2017).

3, 4 (obsolete from September 2017).

Condition 1 Condition 2 Unlubricated fas- Zinc flake silver teners (Dacromet) fasteners.

Zinc fasteners Lubricated zinc and yellow plated fasteners.

Yellow plated fas- Where there is teners a natural lubrication. For example, cast iron components.

Table 42. From September 2017 Type no coating 1 5 7 8 9

Condition 1 Unlubricated fasteners Zinc flake - silver Zinc and heavy trivalent with seal Zinc nickel - silver Zinc nickel - black Zinc flake - black

Condition 2 Dacromet) fasteners.

Zinc flake silver (Dacromet) fasteners.

Verbus-Ripp Bolts Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

Figure 102.

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00 - General

Technical Data

Table 45. Torque Settings - Coarse Metric Grade 8.8 Fasteners

From JCB standard STD00019 issue 15.

1. This information does not apply to:1.1. Hydraulic fittings (i.e. BSP, SAE O-ring boss, UNF, four bolt split flange and JIC).

1.2. Locking type fasteners (those with a nylon insert, or with distorted thread nuts such as Cleveloc).

2. For information on fastener conditions, refer to fasteners and fixings, bolts, general, introduction.

Table 43. Torque Settings - UNF S Fasteners Bolt Size in (1/4 in) (5/16 in) (3/8 in) (7/16 in) (1/2 in) (9/16 in) (5/8 in) (3/4 in) (7/8 in) (1 in) (1 1/8 in) (1 1/4 in)

Treads Hexaper Inch gon (A/ F) in in 28 7/16 24 1/2 24 9/16 20 5/8 20 3/4 18 13/16 18 15/16 16 1 1/8 14 1 15/16 12 1 1/2 12 1 7/8 12 2 1/4

Condition 1

Condition 2

N·m 11.2 22.3 40 64 98 140 196 343 547 814 1,181 1,646

N·m 10 20 36 57 88 126 177 309 492 732 1,063 1,481

in (1/4 in) (5/16 in) (3/8 in) (7/16 in) (1/2 in) (9/16 in) (5/8 in) (3/4 in) (7/8 in) (1 in) (1 1/8 in) (1 1/4 in)

72 - 12

Treads Hexaper Inch gon (A/ F) in in 28 7/16 24 1/2 24 9/16 20 5/8 20 3/4 18 13/16 18 15/16 16 1 1/8 14 1 15/16 12 1 1/2 12 1 7/8 12 2 1/4

Tread Pitch

mm 4 5 6 8 10 12 14 16 20 24 30 36

mm 0.7 0.8 1 1.25 1.5 1.75 2 2 2.5 3 3.5 4

Hexagon (A/ F) mm 7 8 10 13 17 19 22 24 30 36 46 55

Condition 1

Condition 2

N·m 2.9 5.8 9.9 24 47 83 132 205 400 690 1,372 2,399

N·m 2.6 5.2 9 22 43 74 119 184 360 621 1,235 2,159

Table 46. Torque Settings - Coarse Metric Grade 10.9 Fasteners

Table 44. Torque Settings - UNF X Fasteners Bolt Size

Bolt Size

Condition 1

Condition 2

N·m 17.6 35.2 64 101 155 221 310 542 864 1,285 1,865 2,598

N·m 15.9 31.6 57 91 139 199 279 488 777 1,156 1,679 2,339

Bolt Size

Thread Pitch

mm 4 5 6 8 10 12 14 16 20 24 30 36

mm 0.7 0.8 1 1.25 1.5 1.75 2 2 2.5 3 3.5 4

Hexagon (A/ F) mm 7 8 10 13 17 19 22 24 30 36 46 55

Condition 1

Condition 2

N·m 4 8.1 13.9 34 67 116 185 288 562 971 1,930 3,374

N·m 3.6 7.3 12.5 30 60 104 167 259 506 874 1,737 3,036

Table 47. Torque Settings - Coarse Metric Grade 12.9 Fasteners Bolt Size

Thread Pitch

mm 4 5 6 8 10 12 14 16

mm 0.7 0.8 1 1.25 1.5 1.75 2 2

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Hexagon (A/ F) mm 7 8 10 13 17 19 22 24

Condition 1

Condition 2

N·m 4.8 9.8 16.6 40 80 139 223 345

N·m 4.4 8.8 15 36 72 125 200 311 72 - 12

72 - Fasteners and Fixings 06 - Bolts

00 - General

Bolt Size

Thread Pitch

mm 20 24 30 36

mm 2.5 3 3.5 4

Hexagon (A/ F) mm 30 36 46 55

Condition 1

Condition 2

N·m 674 1,165 2,316 4,049

N·m 607 1,048 2,084 3,644

Table 48. Torque Settings - Rivet Nuts / Bolts Bolt Size mm 3 4 5 6 8 10 12

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75 - Consumable Products Contents

Page No.

Acronyms Glossary .................................................................................................................................... 75-2 75-00 Consumable Products 75-00-00 General ............................................................................................................................. 75-3 75-09 Fluids 75-09-00 General ............................................................................................................................. 75-7 75-10 Locking Fluids 75-10-00 General ............................................................................................................................. 75-9 75-14 Solvents and Primers 75-14-00 General ........................................................................................................................... 75-13 75-15 Adhesive 75-15-00 General ........................................................................................................................... 75-17 75-16 Sealant 75-16-00 General ........................................................................................................................... 75-23

9823/0100-1 2018-01-17

Acronyms Glossary PTFE

Polytetrafluoroethylene

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75 - Consumable Products

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00 - Consumable Products Contents

Page No.

75-00-00 General ............................................................................................................................. 75-3

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00 - Consumable Products 00 - General

00 - General

Health and Safety

Health and Safety ........................................... 75-3 Technical Data ................................................. 75-5

Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear personal protective equipment.

Hold a piece of cardboard close to suspected leaks and then examine the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.

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

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

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

Whenever you are handling oil products you must maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Storage Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

Waste Disposal CAUTION It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.

Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.

All waste products must be disposed of in accordance with all the relevant regulations.

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

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

Used oil can contain harmful contaminants.

Eyes

Swallowing

Here are precautions to protect your health when handling used oil: Avoid prolonged, excessive or repeated skin contact with used oil Apply a barrier cream to the skin before handling used oil. Note the following when removing oil from skin: •

• • • •

First Aid - Electrolyte In the case of eye contact, flush with water for 15 min. always get medical attention.

Used Oil

•

WARNING Do not use water to put out an oil fire.

This will only spread it because oil floats on water.

Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam.

New Oil

•

Fires

Wash your skin thoroughly with soap and water • Using a nail brush will help • Use special hand cleansers to help clean dirty hands • Never use petrol, diesel fuel, or paraffin for washing Avoid skin contact with oil soaked clothing Don't keep oily rags in pockets Wash dirty clothing before re-use Throw away oil-soaked shoes

Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

Skin Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

First Aid - Oil Eyes In the case of eye contact, flush with water for 15 min. If irritation persists, get medical attention.

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

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

Spillage Absorb with sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

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Technical Data Table 49. Lubricants and Capacities Item

Capacity

Fluid/ Lubricant

Litres 8.0

UK Gals 1.76

Hubs (x2) SD55 (Brakes)

2.0

0.44

SD40 (No Brakes) SD55 (No Brakes) SD70 (No Brakes) Grease points Brake system

1.0 1.8 2.0 -

0.22 0.40 0.44 -

Axle - SD55/NT Housing

International Specification

Q8 EL3857/ Mobil Fluid 424

API GL4, M2C41B/134D, F M1135/M1141/ M1143 Q8 EL3857 SAE90 / API GL4, Mobil Fluid 424 M2C41B/134D, MF M1135/M1141/ M1143 Q8 T35 SAE90 / API-GL5, MILMobilube HD90 L2105C Mobil HP222 Mobil DTE 11M

(1)

Mobil HP222 ISO VG 15

(1) Caution: Do not use ordinary brake fluid (J1703).

Important: Q8 EL3857/ Mobil 424 should always be used for axles installed with brakes. For axles without brakes Q8 T35 SAE90/ Mobilube HD90 or Q8 EL3857/ Mobil Fluid 424 can be used.

Important: For axles with limited slip differential, Q8 EL3857/ Mobil Fluid 424 must be used.

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09 - Fluids

09 - Fluids Contents

Page No.

75-09-00 General ............................................................................................................................. 75-7

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09 - Fluids

00 - General

00 - General Introduction It is most important that you read and understand this information and the publications referred to. Make sure all your colleagues who are concerned with lubricants read it too.

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

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

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

Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Storage Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

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

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

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10 - Locking Fluids

10 - Locking Fluids Contents

Page No.

75-10-00 General ............................................................................................................................. 75-9

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10 - Locking Fluids 00 - General

00 - General

Introduction

Introduction ...................................................... 75-9 Technical Data ............................................... 75-10

All locking fluids should be used at all times in line with the manufacturer’s recommendations.

Locking fluids are used for the locking of threaded fasteners and for the retention of ball & roller bearings and similar cylindrical items on to shafts and into housings. These fluids consist of an anaerobic resin in a liquid form which hardens when confined between closely fitting metal to metal and many metal to non-metal surfaces.

The fluids available possess a wide span of break-loose strengths, viscosities and gap filling properties and are marketed for a variety of locking and retaining purposes requiring different strength grades. Some of the sealants in use in JCB are also of anaerobic resin type and only differ from the locking fluids in respect of viscosity and other technical details.

Strength grades Various strength grades of fluid are available, the highest strength type for permanent locking where disassembly is unlikely, medium strength for permanent locking but allowing disassembly with ordinary tools and low strength for locking of components where frequent adjustment or easy dismantling is required.

It is recommended that trials be carried out before scheduling locking fluids for any new type of application that has not been already proved as satisfactory in production or when use at elevated temperatures is intended.

Additional technical information is normally available from the product manufacturers.

Approved locking fluids The table shown in Technical Data shows the approved locking fluids available to use on JCB machines. The table also provides basic details to help with selection of locking fluids. More up to date information can be found on the manufacturer’s website.

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10 - Locking Fluids 00 - General

Technical Data Table 50. Locking Fluids Approved Product Information Subsection High strength

Commer- Product Colour cial name Number Loctite 4101/0100 Green (1) fluores270 cent R.A.S. Red threadlock (1) for studs High Loctite 4101/1400 Green, strength 638 UV fluorescent

Shelf Strength life 365 80 –120 bar d ( 1,159.4 – 1,739.1 psi) breakaway strength

For the retention of threads up to M20 diameter where disassembly is unlikely and for locking bearings etc. onto shafts and into housing. Has a maximum gap fill of 0.05 mm.

365 d

Maximum gap fill of 0.25 mm. Maximum strength at room temperature.

High Perstrength mabond (1) A115 Loctite 262

4101/0500 Red, flu- 365 oresd cent

High Loctite strength 648(1) Permabond A118

4101/0600 Green, 365 fluores- d cent

High Loctite strength 2701

4101/1700 Green

365 d

Medium Loctite to high 243

4101/1100

Blue

365 d

Medium Perstrength mabond (1) A119

4101/0900 Blue

365 d

Medium Loctite strength 640

4101/1200 Green, 365 fluores- d cent

75 - 10

More than 250 bar ( 3,623.2 psi) compressive shear strength 100 – 150 bar ( 1,449.3 – 2,173.9 psi) prevailing strength More than 250 bar ( 3,623.2 psi) compressive shear strength 260 – 500 bar ( 3,768.1 – 7,246.3 psi) breakaway torque 140 – 340 bar ( 2,029.0 – 4,927.5 psi) breakaway torque 80 –120 bar ( 1,159.4 – 1,739.1 psi) static shear strength 150 – 330 bar ( 2,173.9 – 4,782.6 psi) static shear strength

9823/0100-1

Comments

Fast curing ( 10 –15 min) thread locking up to M20, especially for use on oily surfaces, plated and clean parts.

Designed for holding gears and sprockets onto gearbox shafts and rotors on electric motor shafts.

Designed for permanent locking and sealing of threaded fasteners. Particularly suited for use on inactive substrates and/or where maximum resistance to hot oil is required.

Suitable for all nuts, bolts, screws up to M36.

Maximum gap fill of 0.25 mm. Handling strength in 10 –15 min.

Product has a slow cure rate, used on parts unlikely to be disassembled.

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10 - Locking Fluids 00 - General

Subsection Medium strength

Commer- Product cial name Number Loctite 4101/0200 (1) 242 Permabond A1042 Permabond A113

Colour

Shelf Strength life Blue, 365 80 –120 bar fluores- d ( 1,159.4 – cent 1,739.1 psi) static shear strength

Low Loctite strength 222

4101/0300 Purple, 365 fluores- d cent

Low Perstrength mabond A1098

4101/1500 Blue

365 d

Low Loctite strength 567

4101/1600 Offwhite

365 d

Very low Loctite strength 932(1) Permabond A011

4101/0400 Brown/ red

365 d

Comments

Suitable for all nuts, bolts and screws up to M36 and hydraulic fittings up to 25mm in diameter. Permabond A113 and A1042 are the preferred choices. The difference between A113 and A1042 is timing for handling and working strength. A113 handling time 10 –25 min, working strength 1 h.

A1042 handling time 5 –10 min, working strength 30 min.

15 –40 bar For screwed fasteners up to M20 that re( 217.4 – quire easy disassembly or frequent ad579.7 psi) justment. Maximum gap fill of 0.05 mm.

Achieves handling strength in 10 –30 min.

120 bar Allows dismantling of parts for mainte( 1,739.1 nance. Suitable for sealing small hydraulic psi) shear and pneumatic fittings. Handling strength in strength 5 –10 min.

17 bar For the locking and sealing of metal ta( 246.4 psi) pered threads and fittings. High lubricatbreakaway ing properties prevent galling on stainless torque steel, aluminium and all other metal pipe threads and fittings.

7 –18 bar Can be disassembled with hand tools. 10 ( 101.4 –30 min cure time for handling strength.

–260.9 Used on large diameter screw threads bigpsi) averger than 50mm. age shear strength

(1) This is a non preferred product.

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14 - Solvents and Primers

14 - Solvents and Primers Contents

Page No.

75-14-00 General ........................................................................................................................... 75-13

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14 - Solvents and Primers 00 - General

00 - General

Introduction

Introduction .................................................... 75-13 Technical Data ............................................... 75-14

This section contains information on primers, solvents, cleaning solutions etc. that are in use at JCB. All primers and solvents should be used at all times in line with the manufacturer’s recommendations.

Approved primers and solvents The table shown in Technical Data shows the approved primers and solvents available to use on JCB machines. The table also provides basic details to help with the selection of primers and solvents.

More up to date information can be found on the manufacturer’s website.

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14 - Solvents and Primers 00 - General

Technical Data Table 51. Primers and Solvents Approved Product Information Subsec- Commer- Product Colour tion cial name Number Activa- Loctite 332/U7901 Colourtor/Primer 770 less

Shelf life 365 d

Activator Loctite 7455

4104/1700 Clear amber

730 d

Activator Loctite 7471 Permabond A905 Water Loctite proofing water proofing Solvent Loctite 7063

4104/0200 Colour- 365 less d

Cleaning Loctite fluid 7070

4101/2200 Colour- 365 less d

4104/0500 -

-

4104/1500 Colour- 365 less d

Cleaning Simple 332/E9240 fluid green extreme Applica- A4GBCJCB4104/3300 tion fluid Gasket Loctite 4104/3200 cleaner 7200

Colour- 365 less d Blue

730 d Colour- 730 less d

Hand cleaner

Loctite 7855

Hand cleaner

Sika hand 4104/1300 Off cleaner white

75 - 14

-

4104/3100 Light grey

540 d

-

Drying Comments Time Less than 5 Used to make low energy surfaces suits able for bonding with cyanocrylate adhesives. It is recommended for polyethylene, polypropylene, PTFE and thermoplastic rubber materials. Can be used with Loctite 406 (332/U7899).

Apply and HIGHLY FLAMMABLE. Organic acceleraleave to dry tor, non CFC solvent based surface activafor 30 s be- tor. Designed to promote the speed of cure fore apply- of cyanoacrylic adhesives. ing adhesive 1 –3 min Used with anaerobic products it increases cure speed. Recommended for inert surfaces and large bond gaps.

A water proofing solution for protecting joints made using cyanoacrylate adhesive.

Apply to Loctite 495 (4103/0900).

1 min at 20 HIGHLY FLAMMABLE, cleaner and de°C ( 68.0 greaser. Removes grease, oil and dirt from °F) electrical parts, tools and precision equipment.

No wipe Cleaning treatment to remove most greas5 –10 min, es, oils, lubrication fluids and metal cuttings post wipe 1 –2 min An all purpose cleaner and degreaser used diluted in water for direct, spray and dip tank procedures.

Vinyl labels application fluid for use with the insignia/livery labels.

Allow 10 – This is a product to aid the removal of 15 min for cured chemical gaskets. Apply for time gasket, 30 specified and remove gasket with soft min for sil- scraper. icone gasket.

Is a heavy duty hand cleaner, specially formulated for the most difficult to remove soils like polyurethane, paints, primers, adhesives etc. The product is free from silicone and harsh solvents. Can be used without water.

A non-abrasive hand cleaner for use when using direct glazing materials.

9823/0100-1

75 - 14

75 - Consumable Products

14 - Solvents and Primers 00 - General

Subsection Direct glazing

Commer- Product Colour cial name Number Sika acti- 4104/2100 Clear vator

Shelf life 365 d

Drying Time 10 min minimum drying time

Direct glazing

Sika re4104/1900 mover 208 (use 4104/3600) Sika 4104/1200 cleaner 205 (use 4104/3600) Sika 4104/2300 primer 209 (use 4104/3500)

Transparent

-

-

Clear

-

-

Black

270 d

Direct glazing Direct glazing

Direct glazing

Active wipe for surface Direct glazing

Cleaner

75 - 15

Application temperature 10 –35 °C ( 50.0 –95.0 °F) Sika akti- 4104/2400 Clear 365 10 min at vator d more than 15 °C ( 59.0 °F) or 30 min at less than 15 °C ( 59.0 °F) Tero4104/3400 Colour- 270 Minimum stat 8560 less d 30 s and AC-25 maximum 1 h Terostat 4102/3500 Black 0.1 L Approx. 2 8519 P bot- min tle = 365 d.

0.01 L and 0.035 L bottle = 540 d Teroson 4104/3600 Clear 730 DependFL cleand ing on coner ditions between 2 – 10 min.

9823/0100-1

Comments HIGHLY FLAMMABLE. A cleaning and activating agent specifically formulated for the treatment of bonded faces in direct glazing applications prior to applying the direct glazing adhesive.

A cleaning agent for removing contaminates on painted surfaces and glass.

A cleaning agent for removing contaminates on painted surfaces and glass.

Used to prime painted surfaces and plastic substrates prior to bonding with Sikaflex products.

Used to clean and give improved adhesion on glass, ceramic-coated glass, the cut face of old polyurethane adhesive beads, polyurethane coated windows glass and paints.

Applied with a clean cloth to the surface, the adhesive may then be applied after the drying time. Applied to glass or ceramic coating but only in the bonding area.

Used to promote adhesion in direct glazing to glass and glass ceramics.

Used for degreasing and cleaning of substrates prior to application of adhesives and sealants.

75 - 15

75 - Consumable Products

15 - Adhesive

15 - Adhesive Contents

Page No.

75-15-00 General ........................................................................................................................... 75-17

75 - 16

9823/0100-1

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75 - Consumable Products

15 - Adhesive 00 - General

00 - General

Introduction

Introduction .................................................... 75-17 Technical Data ............................................... 75-18

All adhesives should be used at all times in line with the manufacturer’s recommendations.

Adhesives are used for the bonding of a number of engineering materials used in production at JCB. Many types are available on the market but in the interests of variety reduction and economy only a limited selection is purchased for regular use.

Types of adhesive Various types of adhesive are covered by JCB Standards: 1. General purpose adhesives for laminated plastics, wood, rubber themselves and to each other.

bonding etc. to

2. The more expensive cyanoacrylate adhesives for use where high strength, resistance to many chemicals and fast cure times are required.

3. Adhesives specially developed for bonding of foam rubber to painted metal surfaces.

Additional health cyanoacrylates

and

safety

for

These adhesives require very careful handling on account of their exceptional properties. They bond together strongly and rapidly to most surfaces including body tissue, the curing process being initiated by surface moisture. For further information on cyanoacrylates refer to the Manufacturer’s recommendations.

Approved adhesives The tables shown in Technical Data are the approved adhesives available to use on JCB machines. The tables also provide basic details to help with the selection of adhesives. More up to date information can be found on the manufacturer’s website.

75 - 17

9823/0100-1

75 - 17

75 - Consumable Products

15 - Adhesive 00 - General

Technical Data Table 52. Adhesives Approved Product Information Subsection High strength

Commer- Product Colour cial name Number Per4103/3100 Mixed mabond grey 5002

Shelf Technical life data 730 d 3 –5 min for handling strength

High Loctite strength 601

4103/1000 Green 365 d fluorescent

Cyanoacrylate

Loctite 424

4103/3500 Colour- less to straw

Cyanoacrylate

Loctite 401

4103/2300 Colour- 180 d less

Cyanoacrylate

Loctite 406

332/U7899 Colour- 180 d less

Cyanoacrylate

Loctite 410

4103/2400 Black

120 d

Cyanoacrylate

Loctite 480

4103/3800 Black

-

Cyanoacrylate

Two part adhesive mixed in equal parts. A toughened adhesive system which bonds metals, plastics, wood, glass, ceramics and composites; even plated or coated surfaces can be securely fastened.

16 –30 bar This product is a single component anaero( 231.9 – bic adhesive. Used to bond cylindrical fitting 434.8 psi) parts, particularly where low viscosity is restatic shear quired. Maximum gap fill is 0.15 mm. strength 18 –26 bar Suitable for most materials including plastic ( 260.9 and rubber. Takes 30 s to cure to working –376.8 strength. psi) shear strength 18 –26 bar Designed for general purpose use. For use ( 260.9 – on acidic and porous surfaces, reaching 376.8 psi) handling strength in seconds. Materials intensile clude plated metals, composite materials, strength wood, cork, foam, leather and paper.

18 –26 bar Designed for bonding of plastics and elas( 260.9 – tomeric materials where very fast fixturing 376.8 psi) is required. Can be used with Loctite 770 lap shear as a primer (332/U7901) strength 22 bar 0.2 mm, gap fill. A rubber toughened ethyl ( 318.8 psi) cyanoacrylate adhesive with enhanced relap shear sistance to peel and shock. Bonds rubber, strength metals and plastics for use in difficult conditions.

22 –30 bar A rubber toughened adhesive with in( 318.8 – creased flexibility and peel strength along 434.8 psi) with enhanced resistance to shock. lap shear strength 12 h maxi- High speed bonding, suitable for rubber to mum cure itself and other materials reaching handling time strength in a matter of seconds. Joint must be waterproofed with Loctite water proofing (4104/0500).

Loctite 4103/0900 Colour- 270 d 495 less Permabond C2 Low Dunlop 4103/1100 Clear 90 d strength 1727 to light straw British vita company VB 165 Acrylic 3M 4941P 4103/3900 Dark 730 d Peel adhefoam grey sion 350 strip adN/ 100 mm hesive

75 - 18

Comments

9823/0100-1

Sprayable adhesive, non-structural applications. For the bonding of flexible foam to themselves, wood, painted metal, chipboard, fibreglass, hessian, felt etc.

High bond acrylic double sided foam tape.

Its allows more complete bond contact area when bonding rigid or irregular materials due to its conformability. Its core adhesive composition makes the product well suited to many paints and primers.

75 - 18

75 - Consumable Products

15 - Adhesive 00 - General

Subsection General purpose gap filling material

Commer- Product Colour cial name Number Araldite 4103/1400 Clear / XD 580 cream

Shelf Technical life data 730 d 560 bar ( 8,115.9 psi) flexural strength

Methacry- Loctite late Speedbonder H3151

4103/3600 Cream to light yellow

Methacry- Plexus late MA420

4103/3700 Off365 d 186 – white or 206 bar blue ( 2,695.6 –2,985.5 psi) 332/S7420 Black 180 d -

Structur- Scotchal plastic weld structural plastic adhesive Non-pre- Evo-Stick 4103/0800 Noneferred 528 preadhesive ferred

Direct glazing

Direct glazing

Direct glazing

75 - 19

-

-

365 d HIGHLY FLAMMABLE

Sika 4103/2100 Black 250PC Sikatack Ultrafast (use 4103/4000 or 4102/4900) Sika 4103/2200 Black 255FC (use 4102/5000)

-

-

-

-

Sikaflex 4103/3200 Black 552 (use 4102/5000)

-

-

9823/0100-1

Comments Two part, equal parts by weight. Wear pad fixing to castings and telescopic components, alignments of fixings pads without expensive machining. This product is a general purpose gap-filling material. Cure time 2 h at 25 °C ( 77.0 °F).

This is a sag resistant, two component, equal parts, methacrylate adhesive system formulated to bond automotive grade cold rolled steel without the use of an external primer. Suitable for bonding a wide variety of plastic and metal substrates. Provides a long open time ( 40 –60 min) for correct aligning of parts.

Two part methacrylate adhesive for structural bonding of thermoplastic, metal and composite assemblies. Combined at 10:1 ratio. It has a working time of 4 –6 min.

Two part acrylic based adhesive (10:1 ratio by vol.) that can bond many low surface energy plastics, including many grades of polypropylene, polyethylene and TPO’s without special surface preparation.

A thin even film of adhesive should be applied to both surfaces being bonded and allowed to become touch dry. This is a contact adhesive and coated surfaces cannot therefore be slid into position since the bond forms on contact. It is often convenient to align the parts along an edge and then bring the two areas into contact.

A one component polyurethane pre-polymer based adhesive. A mastic adhesive which reacts with atmospheric moisture to form a rubber like solid.

For bonding glass to cab frames. A mastic adhesive which reacts with atmospheric moisture to form a rubber like solid. When using this product ensure both surfaces are clean and dry. Use Sika cleaner 205 (4104/1200).

A high performance, elastic, gap, filling one part structural adhesive cures on exposure to atmospheric moisture to form a durable elastomer. Contains no isocyanate.

75 - 19

75 - Consumable Products

15 - Adhesive 00 - General

Subsection Industrial grade epoxy adhesive

Commer- Product cial name Number Loctite 333/Y7062 Hysol E-214 HP

Colour Light Grey Paste

Shelf Technical life data 307 bar ( 4,449.3 psi) tensile strength

Anaero- Scotchbic adweld hesive RT-20 (Dimethacrylate)

333/L9575 Green

365 d -

Direct glazing

Terostat 8597 CT

4102/4900 Black

Direct glazing

Teroson 939CT / Terostat MS939

4102/5000 Black, offwhite, grey, black

Direct glazing

Terostat 8900 HV

4103/4000 Black

540 d in original packaging 365 d in original packaging 180 d 80 bar ( 1,159.4 psi) tensile strength

Direct glazing

Tero4103/4100 Black stat 8594 HMLC

75 - 20

Comments Single component, heat activated formulation develops tough, strong, structural bonds which provide excellent peel resistance and impact strength. When fully cured, the product offers superior thermal shock resistance, excellent mechanical and electrical resistance properties and withstands exposure to a wide variety of solvents and chemicals. Bonds to a wide variety of materials, including metals, glass, ceramics and plastics. Cure at 120 °C ( 247.8 °F) or above until completely firm. Heat up to 150 °C ( 301.8 °F) for 2 h, to maximize properties.

Single component anaerobic adhesives designed to secure cylindrical metal assemblies such as bearings on shafts, bushings, sleeves, housings, and keyways. Help prevent loosening, corrosion and leakage caused by shock and vibration. Full cure time 24 h. Temperature range = - 54 °C ( 129.1 °F) to 450 °C ( 841.4 °F). Not recommended for use on most plastics due to potential cracking of plastic parts.

Cure rate: approx. 3 –4 mm/ 24 h. Glazing time: maximum 20 min (period of time between beginning of material application until inserting of the pane).

Skin formation time: approx. 10 min. Cure rate: approx. 3 mm/ 24 h.

One component, pumpable adhesive/sealant based on polyurethane, which cures by reaction with moisture to an elastic rubber. The skin formation and curing time are dependent on humidity, temperature and depth of joint. High temperature and high moisture reduces curing time.

Sag resistant, temperature range of - 40 °C ( 103.9 °F) to 90 °C ( 193.9 °F).

270 d 85 bar Single component, moisture curing, ad( 1,231.9 hesive/sealant for repair. Product with psi) tensile high shear modulus and low conductivity. strength Suitable for all applications that require very high electrical insulation of the adhesive used for the bonding of windows. Sag resistant.

9823/0100-1

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75 - Consumable Products

15 - Adhesive 00 - General

Subsection Direct glazing

Commer- Product Colour cial name Number Terostat 4103/4200 Black 8900 LV

Direct glazing

Sika 295 UV

75 - 21

4103/4300 Black, white

Shelf Technical life data 365 80 bar d in ( 1,159.4 car- psi) tensile tridges.strength 180 d in sausage pack.

180 d in hobbocks and drums 365 d -

9823/0100-1

Comments One component, pumpable adhesive/sealant based on polyurethane, which cures by reaction with moisture to an elastic rubber. The skin formation and curing time are dependent on humidity, temperature and depth of joint. High temperature and high moisture reduces curing time.

Sag resistant, temperature range of - 40 °C ( 103.9 °F) to 90 °C ( 193.9 °F) short exposure (up to 1 h) of 130 °C ( 265.8 °F).

Direct glazing adhesive for plastic glazing panels. One component polyurethane adhesive of paste like consistency. 60 min tack free time, 1 d cure time ( 4 mm at 23 °C ( 73.4 °F)). Good UV, fresh water and seawater resistance. Do not apply below temperatures of 10 °C ( 50.0 °F) or above 35 °C ( 95.0 °F).

75 - 21

75 - Consumable Products

16 - Sealant

16 - Sealant Contents

Page No.

75-16-00 General ........................................................................................................................... 75-23

75 - 22

9823/0100-1

75 - 22

75 - Consumable Products

16 - Sealant 00 - General

00 - General

Introduction

Introduction .................................................... 75-23 Technical Data ............................................... 75-24

All sealants should be used at all times in line with the manufacturer’s recommendations. Sealants are used mainly for the sealing of screwed joints, sealing flanges and flat surfaces and where gap filling properties are required.

Types of Sealant Various types of sealant are specified in JCB Standards: 1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.

(Flange size and likelihood of dismantling require consideration when selecting this type of sealant).

3. Sealants for use where gap filling properties are required. (The gap dimensions, joint movement if any, type of materials being joined and aesthetic appearance require consideration when selecting this type of sealant).

Approved Sealants The table shown in Technical Data are the approved sealants available to use on JCB machines. The table also provides basic details to help with selection of sealants. More up to date information can be found on the manufacturer’s website.

75 - 23

9823/0100-1

75 - 23

75 - Consumable Products

16 - Sealant 00 - General

Technical Data Table 53. Sealants Approved Product Information Subsec- Comtion mercial name High Loctite strength 275(1) Permabond A140 High Forgestrength way (1) 240FC

Product Number

Medium Loctite to high 620 strength Medium strength

Medium strength

Colour

Shelf Technical life data

4102/0500 Green

730 d 250 bar Non drip formulation, used on larger fittings, ( 3,623.2 coarse threads. psi) torque strength (on M8)

4102/3100 Yellow

270 d 25 bar ( 362.3 psi) breaking strength

4102/3500 Green

-

More than 241 bar ( 3,492.7 psi) shear strength Loc4102/2000 Red, flu- 365 d 90 bar tite 518 ores( 1,304.3 Gasket cent psi) tensile Eliminastrength tor Loctite 4102/4100 Red gel, 80 bar 5182 fluores( 1,159.4 cent psi) shear strength

Medium Loctite strength 595

4102/2500 Clear

Medium Loctite 4102/1900 Yellow strength 577(1) Permabond A1044 Medium Loctite 4102/2700 Blue strength 2431

Can be painted over with some 2 pack paint. Maximum width of joint = 35 mm, minimum width = 2 mm, minimum depth = 2 mm. Recommended depth of joint = width of joint.

Used for locating pins in radiator assemblies, sleeves into pump housings and bearings in auto transmissions. Not suitable for plastics. Diametrical clearance: up to 0.2 mm Typically used as form-in-place gasket on rigid flanged connections.

It is manufactured to minimise air bubbles in the package. Used to seal gaskets, housings, cases and covers. It can also be used to repair and replace cut gaskets (up to 0.08 mm in thickness).

365 d 6 mm gap Formulated to withstand weathering and filling extreme temperature cycling. Used for potting, coating and sealing. Can be applied horizontal, vertical and overhead.

365 d 170 bar A fast curing thread sealant used on coarse ( 2,463.8 threads and pipe fittings up to 75 mm psi) break- thread size. Clearance for gap filling 0.8 away mm. torque

365 d 140 – 340 bar ( 2,029.0 –4,927.5 psi) breakaway torque Low Clayton 4102/2200 White 12 h Maximum strength Dewanopaque full seal presdre air cure sure 29 brake bar ( 420.3 sealant psi) SC1252 Low Red 4102/0800 Resistant strength Herto oil metite 75 - 24

Comments

9823/0100-1

Taper thread sealant, non-fluorescing to see oil leaks. Suitable for all taper fittings up to M36.

Seals pipes and plugs against leakage of air, fuels, lubricants and coolants. Hardens to a tough seal resistant to shock and vibration. Easily dismantled.

Non-hardening paste jointing for joints regularly opened for servicing.

75 - 24

75 - Consumable Products

16 - Sealant 00 - General

Subsec- ComProduct tion mercial Number name Low Loctite 4102/1100 strength 572

Colour

Shelf Technical life data

Comments

White 730 d 40 –100 opaque bar ( 579.7 –1,449.3 psi) breakaway torque GasLoc4102/3200 Blue to 0.2 72 h full keting tite 509 green mm strength on medium Gasket gap steel strength Elimifilling nator Flange Sealant GasLoctite 4102/1200 Red 730 d 2 h working (1) keting strength 574 medium Perstrength mabond

Used where slow cure is required to permit component alignment. PTFE (Polytetrafluoroethylene) filler.

Sealant for gaskets

Used to dress new or worn gaskets. Dries slowly, sets to pliable film for easy dismantling.

Rubber jointing compound

Epoxy resin

75 - 25

A136 Loctite 4102/2600 Black FAG 2 / Loctite 5922

365 d Resists pressures up to 345 bar ( 5,000.0 psi) Dow 4102/0900 Clear or 270 d 16.7 bar corning translu( 242.0 781 cent psi) tensile strength Loctite superflex clear RTV3 EVOstick standard industrial clear silicone sealant Dunlop high modulus silicone sealant DP2205 Loc4102/2400 Slightly tite fast coloured / epoxy transsealant parent

9823/0100-1

Easy disassembly, used as form-in-place gasket.

Does not creep or relax after curing, no bolt re-tightening is required. Oil resistant. Ideal for formed in-situ gaskets.

A synthetic rubber joint sealant suitable for joints between non-porous surfaces such as glass and metal, metal and metal where relatively large gap filling properties are required. Suitable for vertical and overhead applications under normal atmospheric conditions. Joint movement approx.+/-12.5%.

Cure time to 6 mm depth in 24 h.

0.05 L container requires special bi-mixer (gun) so it is mixed as dispensed, 0.024 L is mixed by hand.

75 - 25

75 - Consumable Products

16 - Sealant 00 - General

Subsec- Comtion mercial name Room Loctite tempera- 5910, ture vul- Flange canising sealant, RTV Silicon Room Loctite tempera- 5970 ture vulcanising

Product Number

Colour

4102/3400 Metal- lic black paste

4102/4200 Black

Room temperature vulcanising

Loc4102/2900 Black tite superflex black silicone Room Loctite 4102/3700 Grey tempera- 5901 ture vulcanising Room temperature vulcanising Room temperature vulcanising

Shelf Technical life data

Dry to Designed for flange sealing, good resistouch in 40 tance to oils and allows high joint movemin ment.

730 d 18 bar ( 260.9 psi) tensile strength

Used for gaskets. Excellent resistance to engine oils. Typical applications include stamped sheet metal covers (timing covers and oil sumps) where good oil resistance and the ability to withstand high joint-movement are required.

270 d 16 bar Thixotropic allowing easy application, hori( 231.9 zontal, vertical and overhead. Seals against psi) tensile water and many solvents. strength 730 d 14 bar ( 202.9 psi) shear strength

Loctite 5368

4102/3900 Black paste

730 d

Loctite 5366

4102/4000 Clear paste

730 d

Room Hylomar 332/D5695 Black tempera- 607 paste ture vulcanising

540 d

Joining Loctite oil pan to 5900 bedplate

730 d

4102/3800 Black paste

Anti-cor- To mil- 4102/4300 Yellow rosive itary spec TTP-1757B 1CY

75 - 26

Comments

-

Designed specifically for on line, low pressure tests carried out before product begins to cure. Product exhibits excellent resistance to automotive engine oils. Primarily for flange sealing, it withstands high jointmovement requirements.

20 bar Generally used for sealing applications, but ( 289.9 also for bonding and for high temperature psi) tensile protection. strength 20 bar Designed specifically for use as a bond( 289.9 ing agent to ensure perfect sealing, as psi) shear well as bonding and protection. Examples strength are sealing side windows in trains, sealing heat sources (heat exchangers and water heaters) and for protection/insulation of electrical boxes.

40 bar A special purpose adhesive and sealant ( 579.7 that can be used for a variety of applicapsi) tensile tions. It has good resistance to oils and strength aqueous anti-freeze agents, and is particularly suitable for high strength applications in odour sensitive environments.

14 bar JCB Service ONLY. Introduced for joining ( 202.9 the oil pan to the bedplate face during serpsi) shear vice. High resistance to engine oils. The strength joint should be clamped to spread the adhesive and allowed to cure for 7 d before heavy service duty.

Type 1 Used to coat surfaces of dissimilar metals Class C prior to assembly to prevent corrosion. Zinc chromate containing substance ideal for application to joints between aluminium and steel to prevent corrosion and seizure. FOR USE ON MILITARY VEHICLES ONLY.

9823/0100-1

75 - 26

75 - Consumable Products

16 - Sealant 00 - General

Subsec- ComProduct Colour Shelf Technical tion mercial Number life data name GasBondloc 4102/4500 Clear/ Full cure keting B555 Opaque time 24 medium h. 50 bar strength ( 724.6 psi) tensile strength Seam Terolan 4102/4600 Light 90 d sealant 3412 grey AA-25

Direct glazing

Sikaflex 4102/2800 Yellow 221 (use 4102/4800) Sikaflex 4102/2300 Black 252 (use (1) 4102/4700)

-

-

-

-

Direct glazing

Teroson 4102/4700 PU92 CT

Direct glazing

930 4102/4800 Yellow JCB Branded yellow CT

365 d in original packaging 365 d in original packaging

Direct glazing

Terostat 4102/4900 Black 8597 CT

Direct glazing

75 - 27

-

-

9823/0100-1

Comments B555 is an anaerobic gasket sealant. It seals close fitting joints between rigid metal faces and flanges. Tensile strength to ISO 6922.

Serves as a seam sealant between sheet metal butt and overlap joints (interior seems) on vehicle bodies. Can be cured at temperatures of minimum 140 °C ( 283.8 °F) (effective metal temperature) for 15 min. The material is applied to electro-dip coated steel sheets.

Direct glazing one component polyurethane based adhesive and sealant compound.

Tack free time of 50 min.

A one component polyurethane pre-polymer based sealant. For sealing glass to frames. A mastic sealant which reacts with atmospheric moisture to form a rubber like solid.

The substrates must be clean, dry, oil and grease free. Skin formation time: approx.

20 min Cure rate: approx. 4 mm/ 24 h

The substrates must be clean, dry, oil and grease free. It can be necessary to roughen the surface or to use a primer/adhesion promoter to provide optimum adhesion. When manufacturing of plastics, external release agents are often used; these agents must be absolutely removed prior.

Skin formation time : approx. 20 min Cure rate : approx. 4 mm/ 24 h Isocyanate free solution. Designed for use without primer or activator. When you use this sealant on operator station, it should be used with Teroson PU 8519P black primer (and Teroson 450 clear adhesion promoter when specified specially). Cross compatible with all OEM / OES / AAM DGX sealants, including MS and PU chemistry (any remaining bead must be fully cured before application).

75 - 27

75 - Consumable Products

16 - Sealant 00 - General

Subsec- Comtion mercial name Silicone Sisealant - ka/EverHeat re- build sistant Heat Mate GasLoctite ket and 510 sealing

Product Number

Colour

Shelf Technical life data

Comments

-

-

4102/6100 Opaque pink

-

High modulus permanently flexible 100 % silicone. Temperature resistant up to 300 °C ( 571.6 °F). Ideal for sealing industrial and high performance gaskets, oven doors etc.

Introduced for Heavy products India (swing motor/ gearbox face).

4102/5100 Black

(1) This is a non preferred product.

75 - 28

9823/0100-1

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78 - After Sales Contents

Page No.

78-24 Maintenance Schedules 78-24-00 General ............................................................................................................................. 78-3 78-24-03 Maintenance Intervals ...................................................................................................... 78-5 78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6 78-24-09 Functional Tests and Final Inspection .............................................................................. 78-7 78-81 Clothing and Personal Protective Equipment (PPE) 78-81-00 General ............................................................................................................................. 78-9 78-93 Special Tools 78-93-00 General ........................................................................................................................... 78-11 78-93-03 Parts List ........................................................................................................................ 78-12 78-96 Units of Measurement 78-96-00 General ........................................................................................................................... 78-27

9823/0100-1 2018-05-18

Notes:

9823/0100-1 2018-05-18

78 - After Sales

24 - Maintenance Schedules

24 - Maintenance Schedules Contents 78-24-00 78-24-03 78-24-06 78-24-09

78 - 1

Page No. General .............................................................................................................................

Maintenance Intervals ......................................................................................................

Pre-start Cold Checks, Service Points and Fluid Levels ..................................................

Functional Tests and Final Inspection ..............................................................................

9823/0100-1

78-3 78-5 78-6 78-7

78 - 1

Notes:

78 - 2

9823/0100-1

78 - 2

78 - After Sales

24 - Maintenance Schedules 00 - General

00 - General

Introduction

Introduction ...................................................... 78-3 Operation ......................................................... 78-4

WARNING Maintenance must be done only by suitably qualified and competent persons.

Before doing any maintenance make sure the machine is safe, it must be correctly parked on solid, level ground.

To prevent anyone starting the engine, remove the ignition key. Disconnect the battery (by means of the battery isolator if installed) when you are not using electrical power. If you do not take these precautions you could be killed or injured.

A badly maintained machine is a danger to the operator and the people working around the operator. Make sure that the regular maintenance and lubrication tasks listed in the service schedules are done to keep the machine in a safe and efficient working condition.

To ensure the correct functioning of the engine and emissions control system all operation and maintenance must be conducted in accordance with the instructions in this manual. Incorrect operation, maintenance or repair of the engine and emissions control system may lead to reduced product life, loss of performance or malfunctions.

It is the machine owner's responsibility to ensure maintenance is conducted properly in accordance with the requirements in this manual.

Apart from the daily tasks, the schedules are based on the machine running hours. Keep a regular check on the hourmeter readings to correctly gauge the service intervals. When there is no hourmeter installed, use the calendar equivalents to determine the service intervals.

Do not use a machine which is due for a service.

Make sure any defects found during the regular maintenance checks are corrected immediately.

More frequent checks of engine components than the engine manufacturer recommends do not invalidate emissions warranty.

78 - 3

9823/0100-1

78 - 3

78 - After Sales

24 - Maintenance Schedules 00 - General

Operation The schedules show the service tasks which must be done and their intervals.

The services must be done at either the hourly interval or the calendar equivalent, whichever occurs first.

The intervals given in the schedules must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.) shorten the intervals.

Table 54.

Service task can be completed by a competent operator. Details of how to complete the service task are given in the Operator's Manual.

We recommend that a Service Engineer completes the service task. Details of how to complete the service task are given in the Service Manual.

78 - 4

9823/0100-1

78 - 4

78 - After Sales

24 - Maintenance Schedules 03 - Maintenance Intervals

03 - Maintenance Intervals Introduction Table 55.

Interval (h) 10 50 500 1000 2000

78 - 5

Calendar Equivalent Daily Weekly Six months Yearly Two years

9823/0100-1

78 - 5

78 - After Sales

24 - Maintenance Schedules

06 - Pre-start Cold Checks, Service Points and Fluid Levels

06 - Pre-start Cold Checks, Service Points and Fluid Levels Introduction Table 56. AXLES and STEERING Component Operation

10

50

Axle oil lev- Check el (include Hubs when (3) applicable) Axle oil (in- Change clude Hubs when applicable) Drive shafts Security/ Grease Steer axle Check movement/ (4) Shimming Axle pivot Grease and steering (2) joints Cylinders Check - Chrome condition

100

(1)

500

1,000

2,000

(1) Important: First 100 hours Service only, to be completed by your Distributor.

(2) Important: Mobil HP222 Grease must be used at 500 hours intervals. If an alternative grease is used, the service interval must be reduced to 50 hours/ weekly.

(3) Important: Check for leaks every 50 hours, check level if leaking.

(4) Important: Jobs which should be done by a specialist.

Check generally for leaks on all systems, for example, hydraulic, axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with the recommended fluid after repair.

Faults in the braking system must be rectified immediately. Make sure that the correct fluid is used and all equipment is clean and free from water contamination. Under no circumstances should water be allowed to enter the braking system.

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78 - After Sales

24 - Maintenance Schedules

09 - Functional Tests and Final Inspection

09 - Functional Tests and Final Inspection Introduction Table 57. Functional Test and Final Inspection Component

Operation

AXLES and STEERING Steering modes - Operation

Check

Wheel nut torque

Check

10

50

100 (1)

500 1,000 2,000

Check

Steer phasing

(2)

Steer cylinders - Balance

Check

Steer circuit pressure

Check

(2)

(2)

(1) Important: First 100 Hours service only, to be completed by your Distributor.

(2) Important: Jobs which should be done only by a Specialist person.

Important: Check generally for leaks on all systems, for example, hydraulics, axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with the recommended fluid after repair.

Important: Faults in the braking system must be rectified immediately. Make sure the correct fluid is used and all equipment is clean and free from water contamination. Under no circumstances should water be allowed to enter the braking system.

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78 - After Sales

81 - Clothing and Personal Protective Equipment (PPE)

81 - Clothing and Personal Protective Equipment (PPE) Contents

Page No.

78-81-00 General ............................................................................................................................. 78-9

78 - 8

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78 - After Sales

81 - Clothing and Personal Protective Equipment (PPE) 00 - General

00 - General Introduction Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing and personal safety equipment issued or called for by the job conditions, local regulations or as specified by your employer.

78 - 9

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78 - After Sales

93 - Special Tools

93 - Special Tools Contents

Page No.

78-93-00 General ........................................................................................................................... 78-11 78-93-03 Parts List ........................................................................................................................ 78-12

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78 - After Sales

93 - Special Tools 00 - General

00 - General Introduction The tools shown are the special tools required for completing the procedures described in this manual.

These tools are available from JCB Service or in some instances can be manufactured locally.

The tools are divided into three categories: • • •

Special Tool = Only available from JCB. Recommended Tool = Available from JCB but other tool manufacturers/suppliers may offer a tool with the same characteristics.

General Tool = A tool which is widely available.

Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Before you start work, make sure that all safety precautions are observed in accordance with the information contained within the relevant support documentation.

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78 - After Sales

93 - Special Tools 03 - Parts List

03 - Parts List

Introduction

Introduction .................................................... 78-12 Component Identification ............................... 78-14

27 - Driveline Tool Category General Tool Special Tool Special Tool General Tool

Part No. 892/00179 892/00224 892/00225 892/00333

Special Tool General Tool Special Tool Special Tool Special Tool Special Tool Special Tool Special Tool Special Tool Special Tool General Tool

892/00812 892/00822 892/00918 892/01092 921/52600 921/53300 921/M0229 992/07608 992/07609 993/59500 993/70111

Special Tool Special Tool

997/11000 998/M1374

Special Tool

998/M1375

Description Bearing Press Impulse Extractor Bearing Removal Tool Heavy Duty Socket 19mm A/F x 3/4 in Drive Drive Coupling Spanner Splined Bolt Socket Setting Tool Kit Wheel Hub Service Kit Spacer Kit Spacer Kit Shim Kit Adaptor Bearing Adaptor Adaptor Torque Wrench (10-100Nm) Support Bracket Reaction Plate M14 Studs Reaction Plate

Qty. 1 1 1 1

Description Ram Protection Sleeve (90mm rod diameter) Temperature Probe Ram Seal Installation Tool Ram Protection Sleeve (25mm rod diameter) Ram Protection Sleeve (30mm rod diameter) Ram Protection Sleeve (40mm rod diameter) Ram Protection Sleeve (50mm rod diameter) Ram Protection Sleeve - Slew (50mm rod diameter) Ram Protection Sleeve (60mm rod diameter)

Qty. 1

Comments

1 1 1 1 1 1 1 1 1 1 1 1 4 1

30 - Hydraulic System Tool Category Special Tool

Part No. 892/00167

Special Tool Special Tool

892/00285 892/00334

Special Tool

892/01016

Special Tool

892/01017

Special Tool

892/01018

Special Tool

892/01019

Special Tool

892/01020

Special Tool

892/01021

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Comments

1 1 1 1 1 1 1 1

78 - 12

78 - After Sales

93 - Special Tools 03 - Parts List

Tool Category Special Tool

Part No. 892/01022

Special Tool

892/01023

Special Tool

892/01024

Special Tool

892/01025

Special Tool

892/01026

Special Tool

892/01027

Special Tool

993/99512

Special Tool

993/99513

Special Tool

993/99514

Special Tool

993/99515

Special Tool

SSP0046

Special Tool

SSP0047

78 - 13

Description Ram Protection Sleeve - Slew (60mm rod diameter) Ram Protection Sleeve (65mm rod diameter) Ram Protection Sleeve (70mm rod diameter) Ram Protection Sleeve (75mm rod diameter) Ram Protection Sleeve (80mm rod diameter) Ram Seal Assembly Tool Ram Piston Nut Removal Installation Spanner 55mm A/F Ram Piston Nut Removal Installation Spanner 60mm A/F Ram Piston Nut Removal Installation Spanner 65mm A/F Ram Piston Nut Removal Installation Spanner 70mm A/F Ram Piston Nut Removal Installation Spanner 80mm A/F Ram Piston Nut Removal Installation Spanner 95mm A/F

9823/0100-1

Qty. 1

Comments

1 1 1 1 1 1 1 1 1 1 1

78 - 13

78 - After Sales

93 - Special Tools 03 - Parts List

Component Identification Special Tool - 892/00167 - Ram Protection Sleeve (90mm rod diameter)

General Tool - 892/00179 - Bearing Press

Special Tool - 892/00224 - Impulse Extractor

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 892/00225 - Bearing Removal Tool

Special Tool - 892/00285 - Temperature Probe

General Tool - 892/00333 - Heavy Duty Socket 19mm A/F x 3/4 in Drive

Special Tool - 892/00334 - Ram Seal Installation Tool

78 - 15

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 892/00812 - Drive Coupling Spanner

PTO coupling spanner for yoke type couplings.

General Tool - 892/00822 - Splined Bolt Socket

Special Tool - 892/00918 - Setting Tool Kit

1

1a

1b

Item 1a

Part No. 892/01164

1b

892/01165

1c

892/01163

1d 1e

998/11350 998/11351

1e

998/11352

1c

1d

Description Adaptor (PS760 2004) Sleeve (PS760 2004) Support Bracket (PS760 - 2004) Adaptor Sleeve (40 series drivehead - front axles) Sleeve (40 series drivehead - rear axles)

Qty. 1 1 1 1 1 1

1e

Special Tool - 892/01016 - Ram Protection Sleeve (25mm rod diameter)

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 892/01017 - Ram Protection Sleeve (30mm rod diameter)

Special Tool - 892/01018 - Ram Protection Sleeve (40mm rod diameter)

Special Tool - 892/01019 - Ram Protection Sleeve (50mm rod diameter)

Special Tool - 892/01020 - Ram Protection Sleeve - Slew (50mm rod diameter)

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 892/01021 - Ram Protection Sleeve (60mm rod diameter)

Special Tool - 892/01022 - Ram Protection Sleeve - Slew (60mm rod diameter)

Special Tool - 892/01023 - Ram Protection Sleeve (65mm rod diameter)

Special Tool - 892/01024 - Ram Protection Sleeve (70mm rod diameter)

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 892/01025 - Ram Protection Sleeve (75mm rod diameter)

Special Tool - 892/01026 - Ram Protection Sleeve (80mm rod diameter)

Special Tool - 892/01027 - Ram Seal Assembly Tool

7m m 11o 20m m

10m m

5m m mm R3

110m m 175m m 3o R

78 - 19

1.

4m

m

9823/0100-1

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 892/01092 - Wheel Hub Service Kit

A

5 1 6

8, 9

7

10

2 3 4

B

13,23 15 19,20

14 16

C 18 17 21

78 - 20

8

Item A B C

Part No.

1 2 3 4 5 6

998/M5626 998/1067 1315/3731Z 1370/0601Z 998/10614 998/10624

7 8 9 10 11 12 13

1370/0701Z 1370/0701 1420/0012Z 998/10610 1370/0401Z 1420/0009Z 998/10608

9823/0100-1

Description Bearing Puller Bearing Press Seal Dolly comprises: Puller Beam Clamp Plates Bolt M16 x 220mm Nut M16 Reaction Tube Modified Wheel Stud Puller Leg Nut M20 Washer M20 Rod Nut M12 Washer M12 Bearing Centre Puller

Qty. 1 1 1 1 1 2 2 1 2 2 4 4 2 2 2 1 78 - 20

78 - After Sales

93 - Special Tools 03 - Parts List

Item 14 15 16 17 18 19 20 21 22 23

Special Tool - 921/52600 - Spacer Kit

78 - 21

Part No. Description 1315/3414Z Bolt M10 1370/0301Z Nut M10 Reaction Tube (same part as item 5) 998/10616 Handle Nut 1315/3833Z Bolt M20 445/12303 Washer 917/02800 Bearing 892/00891 Seal Dolly 998/10609 Bearing Installation Tube 998/M5629 Bearing Centre Puller (87 Series)

Qty. 1 1 1 1 2 2 1 1 1 1

After using a spacer, obtain a replacement to keep the set complete.

Item 1

Part No. 921/52628

2

921/52629

3

921/52630

4

921/52601

5

921/52602

6

921/52603

7

921/52604

8

921/52605

9

921/52606

10

921/52607

11

921/52608

12

921/52609

13

921/52610

14

921/52611

15

921/52612

16

921/52613

9823/0100-1

Description Spacer 12.60mm thick Spacer 12.65mm thick Spacer 12.7mm thick Spacer 12.75mm thick Spacer 12.80mm thick Spacer 12.85mm thick Spacer 12.9mm thick Spacer 12.95mm thick Spacer 13.00mm thick Spacer 13.05mm thick Spacer 13.10mm thick Spacer 13.15mm thick Spacer 13.20mm thick Spacer 13.25mm thick Spacer 13.30mm thick Spacer 13.35mm thick

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 921/53300 - Spacer Kit

78 - 22

Item 17

Part No. 921/52614

18

921/52615

19

921/52616

20

921/52617

21

921/52618

22

921/52619

23

921/52620

24

921/52621

25

921/52622

26

921/52623

27

921/52624

28

921/52625

29

921/52626

30

921/52627

Description Spacer 13.40mm thick Spacer 13.45mm thick Spacer 13.50mm thick Spacer 13.55mm thick Spacer 13.60mm thick Spacer 13.65mm thick Spacer 13.70mm thick Spacer 13.75mm thick Spacer 13.80mm thick Spacer 13.85mm thick Spacer 13.90mm thick Spacer 13.95mm thick Spacer 14.00mm thick Spacer 14.20mm thick

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1

After using a spacer, obtain a replacement to keep the set complete.

Item 1

Part No. 921/53322

2

921/53323

3

921/53324

4

921/53325

5

921/53301

6

921/53302

7

921/53303

8

921/53304

9

921/53305

10

921/53306

9823/0100-1

Description Spacer 13.55mm thick Spacer 13.575mm thick Spacer 13.6mm thick Spacer 13.625mm thick Spacer 13.65mm thick Spacer 13.675mm thick Spacer 13.7mm thick Spacer 13.725mm thick Spacer 13.75mm thick Spacer 13.775mm thick

Qty. 1 1 1 1 1 1 1 1 1 1 78 - 22

78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 921/M0229 - Shim Kit

Item 11

Part No. 921/53307

12

921/53308

13

921/53309

14

921/53310

15

921/53311

16

921/53312

17

921/53313

18

921/53314

19

921/53315

20

921/53316

21

921/53317

22

921/53318

23

921/53319

24

921/53320

25

921/53321

Description Spacer 13.80mm thick Spacer 13.825mm thick Spacer 13.850mm thick Spacer 13.875mm thick Spacer 13.90mm thick Spacer 13.925mm thick Spacer 13.950mm thick Spacer 13.975mm thick Spacer 14.00mm thick Spacer 14.025mm thick Spacer 14.050mm thick Spacer 14.075mm thick Spacer 14.10mm thick Spacer 14.125mm thick Spacer 14.150mm thick

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

After using a shim, obtain a replacement to keep the set complete.

Item 1 2 3 4 5

Part No. 921/M0230 921/M0231 921/M0232 921/M0233 921/M0234

Description Shim 0.15mm thick Shim 0.2mm thick Shim 0.25mm thick Shim 0.5mm thick Shim 1.0mm thick

Qty. 1 1 1 1 1

Special Tool - 992/07608 - Adaptor Special Tool - 992/07609 - Bearing Adaptor

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78 - After Sales

93 - Special Tools 03 - Parts List

Special Tool - 993/59500 - Adaptor General Tool - 993/70111 - Torque Wrench (10-100Nm)

Special Tool - 993/99512 - Ram Piston Nut Removal Installation Spanner 55mm A/F

Special Tool - 993/99513 - Ram Piston Nut Removal Installation Spanner 60mm A/F

Special Tool - 993/99514 - Ram Piston Nut Removal Installation Spanner 65mm A/F

Special Tool - 993/99515 - Ram Piston Nut Removal Installation Spanner 70mm A/F

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93 - Special Tools 03 - Parts List

Special Tool - 997/11000 - Support Bracket

Special Tool - 998/M1374 - Reaction Plate M14 Studs

Special Tool - 998/M1375 - Reaction Plate

Special Tool - SSP0046 - Ram Piston Nut Removal Installation Spanner 80mm A/F

Special Tool - SSP0047 - Ram Piston Nut Removal Installation Spanner 95mm A/F

78 - 25

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78 - After Sales

96 - Units of Measurement

96 - Units of Measurement Contents

Page No.

78-96-00 General ........................................................................................................................... 78-27

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78 - After Sales

96 - Units of Measurement 00 - General

00 - General

Table 63. Flow

Technical Data The standard units of measurement used by JCB are listed below together with the formula for conversion for countries using non metric standards.

Table 58. Force Convert to

Multiply by

Kilogram force (kgf) Pound force (lbf)

0.102

Multiply by 0.0394 3.281 1.094 0.621

Convert to

Multiply by

Ounce (oz) Pound (lb) Ton

0.035 2.205 0.984

Measurement (unit) Newton metre (Nm)

Convert to

Measurement (unit) Bar

Measurement (unit) Kilometre/Litre (km/l)

Millilitre (ml) Litre (l) 78 - 27

Convert to

3.281

Square Inch (in²) Square Foot (ft²) Square Yard (yd²)

0.0015 10.764 1.196

Convert to

Multiply by

Pound force foot (lb f ft)

0.7376

Convert to

Multiply by

Pound force/ inch² (psi)

14.5

Convert to

Multiply by

Miles/Gallon (mpg) Miles/ US Gallon

2.825 2.352

Measurement (unit) Degrees Celsius (°C)

Convert to

Formula

Degrees Multiply by 9, Fahrenheit (°F) Divide by 5, Add 32 Table 69. Power

Multiply by

Cubic Inch (in³) 0.061 Cubic Foot (ft³) Cubic Yard (yd³) Fluid ounce (fl oz) UK Gallon US Gallon

Multiply by

Table 68. Temperature

Table 62. Volume Measurement (unit) Cubic Centimetre (cm³) Cubic Metre (m³)

Convert to

Table 67. Fuel Consumption

Multiply by

mile/hour (mph) 0.621 feet/second (ft/ s)

0.264

Table 66. Pressure

Table 61. Speed Measurement (unit) Kilometre/Hour (km/h) Metre/Second (m/s)

0.220

Table 65. Torque

Table 60. Mass Measurement (unit) Gram (g) Kilogram (kg) Tonne

Measurement (unit) Square Millimetre (mm²) Square Metre (m²)

0.225

Table 59. Length Measurement Convert to (unit) Millimetre (mm) Inch (in) Metre (m) Feet (ft) Yard (yd) Kilometre (km) Mile (mile)

Multiply by

Table 64. Area

Standard Units Measurement (unit) Newton (N)

Measurement Convert to (unit) Litre/Minute (L/ UK Galm) lon/Minute US Gallon/Minute

35.315 1.308 0.035 0.220 0.264

Measurement (unit) KiloWatt (kW)

Convert to

Multiply by

Horsepower (hp)

1.341

Table 70. Time Measurement (unit) Second (s) Minute (min) Hour (h) 9823/0100-1

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78 - After Sales

96 - Units of Measurement 00 - General

Table 71. Current Measurement (unit) Ampere (A) Table 72. Voltage Measurement (unit) Volt (V) Table 73. Noise Levels Measurement (unit) Sound pressure level (LpA) Sound power level (LwA)

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