160-170 Mk3 ProbSolv

ROBOT160, 170, 170HF

Problem SolvingClick the problem on the contents list to

take you to the answer

Problem Solving

9803/8520 Issue 1

Contents

The following pages are extracted from the Robot 160, 170 Service Manual 9803/8520.For more information, refer to the Service Manual.

Click on the appropriate title to go to the page. Start with Transmission or Loader Problems and Causes.

Transmission Problems Loader ProblemsTransmission Problems and Causes Loader Problems and CausesChecking for Faulty Pump or Motor CPPV Flow/Pressure CheckChecking Wheel Speed Bleeding the Hydraulic SystemMachine Veers to One Side When Travelling Levelling Circuit Problem SolvingTransmission Pump Neutral Adjustment Main Relief Valve Pressure TestChecking Motor Leakage Rate Loader Valve Dismantling and Assembly - ServoPump Main Pressure Test Points Loader Valve Dismantling and Assembly - ManualPressure Testing Main Relief Valves Suction Strainer Removal and ReplacementChecking Joystick Hydraulic Lines Changing Hydraulic FilterServo Joystick Dismantling and AssemblyTyres and WheelsCharge Pressure Checking and Adjustment - ServoCharge Pressure Checking and Adjustment - ManualReturn to Idle Controls - ManualPump/Engine CouplingDrive Motor Dismantling and AssemblyAdjusting Drive Chain TensionWheel Hub Assembly (Right Hand)Drive Shaft Assembly (Left Hand)

10 - 1

Section E Hydraulics

9803/8520

Section E10 - 1

Issue 2

Problem Solving CONTENTS

Hydrostatic Transmission

The purpose of this section is to help you trace transmission problems to a faulty unit (pump, motor, joystick etc). Once you havetraced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.

* Before you begin problem solving, read the Safety Information at the beginning of this manual.

* Make simple checks before say, stripping a major component.

* Make sure that the hydraulic fluid is at correct working temperature (50 C, 122 F).

* Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

* Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in thecircuit.

PROBLEM CAUSE (servo machines) CAUSE (manual machines)No drive in any direction 1, 2, 4, 10, 17 1, 2, 4, 17No drive in either forward or reverse 1, 2, 6, 9, 11, 12 1, 2, 6, 9, 12No spin turn either left or right 3, 4, 11, 12, 15 3, 4, 11, 15No drive on one side 2, 5, 6, 9, 11, 12, 15, 16 2, 5, 6, 8, 9, 12, 15, 16Machine will not travel in a straight line 3, 7, 9, 11, 12, 13, 14, 15 2, 8, 9, 12, 14, 15Poor drive performance, no tractive effort 4, 5, 6 4, 5, 6Machine creeps in neutral 7 8Machine will not move at idle butmoves at max. revs. 4 4

Hydraulic fluid is overheating 1, 18, 19, 20 1, 18, 19, 20Noise in transmission 16 16

KEY TO CAUSE REMEDY PAGE REF.

1 No oil in hydrostatic system or oil level too low Top-up as necessary.

2 Brake not released Check mechanism.

3 Tyres worn or pressure incorrect Check tyre pressures and condition. 3/9-2

4 Charge pressure low a Standard machines - Adjust charge pressure at Manual E26-4transmission pump. Servo E29-4

b High-flow machines - Charge pressure iscontrolled by the Priority Valve. Carry out flow check. E11-4Check that transmission pump charge valve is disabled.

5 No or low pump output Check pump - carry out wheel speed check. E10-3 &If one pump suspect, swop motor feed hoses and notice E10-4if problem changes sides - if yes, pump related fault;if no, motor related fault.

6 High pressure loop relief valve/tow valve Check that valves have been re-tightened after towing.open/set incorrectly Replace relief valve and re-check. E10-8

7 Pump neutral position set incorrectly Adjust servo neutral position. E10-6

8 Manual controls incorrectly set Adjust manual controls E25-2

..... continued

10 - 1ACONTENTS10 - 1A

Hydrostatic Transmission (contd)KEY TO CAUSE REMEDY PAGE REF.

9 Feed hose failure Check motor feed hoses.

10 No hydraulic feed to joystick Check for feed to joystick. E10-9

11 No hydraulic feed from joystick to pump Check for feed from joystick to pump. E10-9

12 Motor seal leakage Check motor case drain for confirmation of seal leakage E10-7(compare one motor with the other). Check for shaft sealleakage by checking chain case oil level.

13 Joystick inoperative Check joystick (plunger movement, leaking seals, etc.)

14 Chain tension Check chain tension. F5-2

15 Motor failure Inspect motor for damage. Repair as required. E36-1

16 Chain/sprocket damage Inspect chain and sprocket. Repair as required. F4-1

17 Pump/engine drive coupling failure Check coupling. E24-1

18 Oil temperature switch faulty Replace switch.

19 Restriction in oil cooler Carry out flow check. Check for damage to hoses and pipework.Replace oil cooler.

20 Shuttle valve in motor defective Inspect motor and repair as required. E36-1


9803/8520

Section E

Issue 1

Problem Solving

10 - 2


9803/8520

Section E10 - 2

Issue 1


F1T

P3

C

P2 P1

39

1

S1

4

2

PaPb

Pc

Pd

Pe

2a

2b

2c2d

2e

M1

M1a

M2

M2a

321360

X1

X2

X1 326680

X2

332940

10 - 3

Checking for Faulty Pump or Motor

If the transmission operates or is faulty on one side only thenswop the motor feed hoses to check if the fault is with thepump or motor. If, after the hose swop, the suspect motorthen operates the fault lies in the relevant pump unit. If themotor still does not operate then the motor itself is faulty.

Proceed as follows:

1 Stop the engine.

2 Remove the seat and floorplate to expose the pump.

3 To ensure correct replacement after the test is complete,mark the motor feed hoses A and B for the left hand(upper) motor, C and D for the right hand (lower) motor.

4 Swop the motor feed hoses from one side to the other asindicated in the illustration, i.e. swop hoses A and C thenswop hoses B and D.

Note: It may be found more convenient to use separateadditional hoses to extend the existing feed hoses.

5 Restart the engine and re-check the operation of left andright motors. Note that when the left motor is selectedthe right motor should now drive and the left motorshould drive when the right motor is selected. If thepreviously faulty motor now functions then the fault lies inthe relevant pump unit. If the motor still does not operatethen the motor itself is faulty.

! WARNINGHydraulic Fluid

Fine jets of hydraulic fluid at high pressure canpenetrate the skin. Do not use your fingers to check forhydraulic fluid leaks. Do not put your face close tosuspected leaks. Hold a piece of cardboard close tosuspected leaks and then inspect the cardboard forsigns of hydraulic fluid. If hydraulic fluid penetrates yourskin, get medical help immediately.INT-3-1-10/1


9803/8520

Section E10 - 3

Issue 1


A

C

332950

D

B

10 - 4

Checking Wheel Speed

The pump output and general efficiency of the drive systemmay be checked by raising the machine off the ground andchecking the wheel speeds.

! WARNINGThe following procedure requires the machine to bedisabled (wheels raised off the ground, attachmentdisconnected etc.) while the work is carried out.HYD 8-1/2

Place the machine safely onto blocks, so that all four wheelsare clear of the ground. Ensure that the machine is stable.

Stick a piece of reflective tape on a wheel rim. Start theengine and run at maximum speed then operate the drivecontrol. Using a stroboscopic meter, measure the speed ofwheel rotation in each direction which should be 81 rev/min.An allowance of 2% above this figure is permissible. Checkthe speed of the wheels on the opposite side of the machine.

Note that excessive wheel speed may result in coolingproblems due to overheating of the hydraulic oil.

Maximum Displacement Adjustment - Servo Machines

If necessary the appropriate adjusting screws should bescrewed in 1/4 turn at a time until the correct wheel speed isachieved. Stop the engine while adjustment is carried out.

1 Remove the seat and floorplate to expose the pump.

2 If the left hand wheels are rotating too fast, screw inadjusters A (forward) or B (reverse) to achieve thecorrect speed. If the right hand wheels are rotating toofast, screw in adjusters C (forward) or D (reverse).

If all four wheels rotate slowly and cannot be corrected byadjustment, the most likely cause would be internal wear ofthe hydrostatic pump.

If the wheel speed is slow on one side only, the cause couldbe a faulty servo or a faulty motor. Carry out procedure onpage E10-3 to determine which is faulty.

Following this procedure, further small adjustments may berequired to achieve correct straight line travel (see followingpage).

Maximum Displacement Adjustment - Manual Machines

If the correct wheel speed cannot be achieved, check that thecontrol linkage is correctly adjusted and giving maximumpump swash.

If maximum pump swash is achieved and the wheel speed isnot correct, the pump or motor could be faulty. Carry outprocedure on page E10-3 to determine which is faulty.


9803/8520

Section E10 - 4

Issue 2*


332870

C

B

A

D

*

*

10 - 5


9803/8520

Section E10 - 5

Issue 1


Machine veers to one side when travelling.

Adjustment - Servo Machines

If the machine does not travel in a straight line, proceed asfollows:

Refer to illustration on previous page.

Fault

1 Machine veers excessively to left in forward travel

2 Machine veers excessively to right in forward travel

3 Machine veers excessively to left in reverse travel

4 Machine veers excessively to right in reverse travel

Adjustment - Manual Machines

Refer to Return to Idle Controls - Manual Pump.

Loosen locknut on adjuster screw C, screw in adjuster screw1/4 turn and tighten locknut. Try machine. Keep adjusting 1/4turn at a time until straight line travel is achieved.

Proceed as for fault 1 but adjust screw A.

Proceed as for fault 2 but adjust screw D.

Proceed as for fault 3 but adjust screw B.

This condition may be corrected by adjusting the pump servo units or manual controls but before attempting this, carry out thefollowing preliminary checks.

Check tyre pressures The pressure of one tyre may be low or one or both tyres on one side of the machine may be and condition new and the other tyres worn. In both these cases the rolling circumference of the tyres will be

unequal causing the machine to veer to one side.

Check chain tension Chains which are tensioned unequally will cause the machine to veer to one side. Always adjust the tension on all four chains, never just one.

Check the servo joystick Check that the joystick spools are not sticking and are correctly operated by the lever.

Check the manual controls Check that the manual control linkage is not sticking. Lubricate if necessary.

Note: If the fault cannot be rectified by any of the above checks or adjustment, then either the pump or motor could be faulty. Toidentify which, swop the motor feed hoses at the pump as described on page 10-3. If the machine now veers in the oppositedirection then the pump is faulty. If the machine continues to veer in the same direction the motor is faulty.

10 - 6

Transmission Pump Neutral AdjustmentThis procedure may be carried out if the machine creepswhen the drive control is in the neutral position.

Adjustment - Servo Machines

This fault may be due to an incorrect neutral setting of theservo piston.

1 Identify which pump section requires adjustment.

If the machine veers to the left this could be caused byeither the right hand wheels moving forward or the lefthand wheels moving in reverse. Remember that pumpP1 drives the left hand motor and pump P2 drives theright hand motor.

If the machine moves either straight ahead or behindthen both pump servos must be adjusted equally.

2 Stop the engine.

3 Remove the seat, seat base and pump cover.

4 If pump P1 requires adjusting, loosen locknut A and turnthe neutral adjusting screw B 1/10 of a turn in therequired direction then re-tighten the locknut.

If pump P2 is to be adjusted, loosen locknut C and turnadjusting screw D.

If the wheels are creeping forward, turn the adjustingscrews in an anti-clockwise direction (out). If the wheelsare creeping in reverse, turn the screws clockwise (in).

Note: This adjustment is very sensitive. Turn the adjustingscrew 1/10 of a turn at a time and re-check. A slightmovement when the wheels are raised is acceptableprovided that no movement occurs when the machine isresting on the ground.

5 Start the engine and check that the wheels arestationary.

6 Finally tighten locknuts A and C taking care to retain theset position of adjusting screws.

7 Re-check for wheel movement.

Adjustment - Manual Machines

Refer to Return to Idle Controls - Manual Pump.


9803/8520

Section E10 - 6

Issue 1


332960

B

D

P1

P2

A

C

10 - 7

Checking Motor Leakage Rate

If the motor speed is low and the pump output is normal, thecause could be excessive internal wear in the motor whichwould result in high leakage of oil into the motor casing. Bymeasuring the amount of oil leaking from the motor casingback to tank, it is possible to determine if the motor is worn.

1 Stop the engine.

2 Remove the seat and floorplate to expose the motors.

3 Connect a flowmeter into the motor drain hose A(manual pump) or B (servo pump) at the tee connectionon top of the pump.

Note: On High-flow machines the motor drain hoses areconnected into the High-flow oil cooler feed hose at the backof the machine.

4 Install a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)pressure gauge into the appropriate point on the pump tomeasure the pressure generated in the motor feed line(see next page for pressure test points).

5 Start the engine and drive the machine forward against asolid, immovable object as shown at C. Measure theamount of oil expelled from the motor during oneminutes operation.

At the maximum pressure of 385 bar (5582 lbf/in2) the normaloil leakage should be approx. 17 l/min (3.75 UK gal/min, 4.5US gal/min).

Note: The motor leakage at zero pressure is much less thanthe rate at higher pressures. This is because at higherpressures the motor flushing spool is actuated causing the oilflow through the motor casing to increase. The figure quotedabove is the combined leakage and flushing flows.

If the flow rate is higher than normal, the motor should bedismantled for repair.


9803/8520

Section E10 - 7

Issue 2*


332931

C

AC

BD

324241

324880A

A

A

B

B

*

10 - 8

Pump Main Relief Pressure Test Points

Illustration X shows the servo pump. The upper view showsthe right hand side of the pump, the lower view shows the lefthand side of the pump.

Illustration Y shows the manual pump. The upper view showsthe underside of the pump, the lower view shows the lefthand side of the pump.

A Left motor forward portB Left motor reverse portC Right motor reverse portD Right motor forward port

Note: Point D on the manual pump (illustration Y) is on theright side of the pump.

! WARNINGHydraulic Fluid

Fine jets of hydraulic fluid at high pressure canpenetrate the skin. Do not use your fingers to check forhydraulic fluid leaks. Do not put your face close tosuspected leaks. Hold a piece of cardboard close tosuspected leaks and then inspect the cardboard forsigns of hydraulic fluid. If hydraulic fluid penetrates yourskin, get medical help immediately.INT-3-1-10/1

Testing Main Relief Valves

Whilst carrying out this test make sure the area around themachine is clear of personnel.

1 Remove the seat and seat base. Install a 0 - 400 bar (0 -6000 lb/in2, 0 - 422 kg/cm2) pressure gauge into theappropriate point on the pump to measure the pressuregenerated in the motor feed line.

2 Servo machines:

Raise the safety restraint to apply the parking brake andprevent the machine from moving.

Manual machines:

Mark the relative positions of the two sections of thesafety restraint to parking brake link then disconnect thelink so that the restraint can be lowered without releasingthe parking brake.

3 Start the engine and run at max. revs. then operate thetransmission control to select the appropriate drive.

4 The gauge will show the relief pressure setting whichshould be as shown in Technical Data.

If the pressure setting is incorrect, the appropriate valveshould be removed and a new one fitted. The valves are notadjustable.


9803/8520

Section E10 - 8

Issue 2


B

A

C

D

X

327490

C

AB

BC

Y

325410

D

10 - 9

Checking the Joystick Hydraulic Lines

If the machine does not respond to joystick movements,check the hydraulic supply to and from the joystick asfollows:

! WARNINGThe following procedure requires the machine to bedisabled (wheels raised off the ground, attachmentdisconnected etc.) while the work is carried out.HYD 8-1/2

1 Raise and block the machine so that the wheels areclear of the ground. Stop the engine. Make sure themachine is stable.

2 Remove the seat and floorplate to access the hoseconnections A and B.

3 Insert a tee piece and 0 - 40 bar (0 - 600 lb/in2, 0 - 42kg/cm2) pressure gauge into the supply hose at theloader valve at position A.

Note: On High-flow machines the servo supply is taken fromthe lower connection at the charge pressure priority valve.There are two connections, one for the transmission joystickand one for the loader joystick.

4 Start the engine and observe the gauge reading whichshould show the transmission pump charge pressure(see Hydraulics Technical Data).

5 If the gauge shows no or little pressure it could indicate afault in the charge pressure relief valve in the hydrostaticpump or the pressure reducing solenoid valve C.

6 If the supply pressure is correct, check the feed hose tothe joystick for blockage.

7 Remove the tee piece and gauge and connect into eachservo feed line in turn, as shown at B.

8 Start the engine and move the joystick lever topressurise the relevant hose. The lever should be movedfully diagonally as shown below.

9 The pressure gauge should show transmission pumpcharge pressure with full joystick travel (see HydraulicsTechnical Data).

10 If any readings are not correct, check the hoses forblockage. If the hoses are clear the joystick should bedismantled for repair.


9803/8520

Section E10 - 9

Issue 1


FWD

REV

B

332980

333070

A

21

3 4

4

2

3

1

CONTENTS11 - 1


9803/8520

Section E11 - 1

Issue 1

Problem Solving

Loader Circuit

The purpose of this section is to help you trace hydraulic problems to a faulty unit (valve, actuator, ram etc). Once you havetraced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.

To help identify circuits, valves, rams etc. mentioned in the problem solving procedures, refer to hydraulic schematic diagrams.

* Before you begin problem solving, read the Safety Information at the beginning of this manual.

* Make simple checks before say, stripping a major component.

* Make sure that the hydraulic fluid is at correct working temperature (50 C, 122 F).

* Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

* Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in thecircuit.

PROBLEM CAUSE (standard machines) CAUSE (High-flow machines)

Lack of power in all loader functions. 1, 2, 3, 4, 6, 7, 20 1, 2, 3, 4, 6, 7, 8, 20

All hydraulic rams slow to operate. 3, 4, 7 (servo only), 11, 13 3, 4, 8 (servo only), 11, 13

One hydraulic service fails to operate or 14, 15, 16, 17, 19 14, 15, 16, 17, 19is slow to operate.

Engine tends to stall when hydraulics are under load. 3, 20 3, 8, 20

Valve spool sticking. 3, 21, 23, 24, 25, 26, 27, 28, 29, 30 3, 21, 23, 24, 25, 26, 27, 28, 29, 30

Ram creep. 15, 18 15, 18

Hydraulic oil becomes too hot. 5, 6, 12, 22 5, 6, 12, 22

Boom judders when used while machine is moving. 9 (servo only), 13 11, 13


1 Insufficient hydraulic fluid. Check for leaks and top up as required.

2 Hydraulic leaks in system. Check hoses, replace as required.

3 Main relief valve (MRV) setting incorrect. Check and adjust as required. E21-1

4 Low loader pump flow. Check pump flow, if necessary service or replace pump.

5 Hydraulic filter clogged. Change hydraulic filter. 3/8-1

6 Charge filter by-pass valve leaking. Check condition of hydraulic filter. 3/8-1Check operation of by-pass valve.

7 Charge pressure incorrect. Carry out charge pressure check. Manual E26-4Servo E29-4

8 Charge pressure priority valve pressure Check pressure setting of charge pressure priority valve. E11-4setting incorrect.

..... continued

11 - 2


9803/8520

Section E11 - 2

Issue 2*

Problem Solving


9 Servo pressure low Carry out charge pressure check. Check for blocked Manual E26-4service feed hose or faulty joystick. Servo E29-4

10 Non priority pressure/flow low. Carry out charge pressure priority valve flow check. E11-4

11 Neutral circuit or low pressure lines leaking, Check pipe lines and replace as required.damaged, trapped or kinked.

12 Restriction in neutral circuit lines. Check hoses and pipes, replace as necessary.

13 Air in hydraulic system Bleed system. E11-5

14 Service pipe lines leaking, damaged, Check hoses and pipes, replace as required.trapped or kinked.

15 Ram or pipe lines from ram leaking. Check and rectify as required. E56-1

16 Valve spool not operating. Check for leaks, rectify as required. Manual E41-2Make sure that spool lock-out is operating (check forfaulty wiring, solenoid sticking, burr on spool, etc.)Make sure that associated load hold Servo E40-2check valve is operating.

On servo machines, check operation ofjoystick and feed hoses.On manual machines, check that control leverand associated linkage is operating the spool,rectify as required.

17 Valve spool not moving fully from Spool movement should be 5 mm (0.2 in)neutral to full selection. On servo machines, check servo (charge) pressure. E26-3

18 Valve spool leaking Rectify, check for contamination. Manual E41-2Servo E40-2

19 Piston rod bent. Replace piston rod. Check pressure setting of MRV. E56-1Check that associated pivot pins are adequately greased.

20 Poor engine performance. Check engine performance. K1-1

21 Manual control linkage bent. Disconnect linkage. Repair linkage or renew.

22 Oil cooler obstructed. Remove debris from cooler fins.

23 Oil temperature abnormally high. Check for correct fluid, see Lubricants andCapacities. Check oil cooler and grille for blockage.

24 Hydraulic fluid dirty. Clean tank strainer. If strainer badly clogged, drain and E61-1flush hydraulic system then fill with clean hydraulic fluid.

25 Service pipe connection over tightened. Check tightness.

26 Valve housing twisted during installation. Loosen retaining bolts and tighten to correct torque. Manual E41-2Servo E40-2

..... continued

*

CONTENTS

CONTENTS11 - 3


27 Bent spool. Dismantle control valve. Renew spool as necessary. Manual E41-2Servo E40-2

28 Spool return spring broken. Renew as necessary. Manual E41-2Servo E40-2

29 Spool return spring or cap out of alignment. Remove cap, check that spring is in correct position. Manual E41-2Refit cap and torque tighten bolts. Servo E40-2

30 Temperature distribution within Warm up entire system before using service.control valve not uniform.


9803/8520

Section E11 - 3

Issue 1

Problem Solving

11 - 4

1 Install a flow meter and 0 - 40 bar (0 - 600 lb/in2, 0 - 42kg/cm2) pressure gauge into the priority line from theCharge Pressure Priority Valve (CPPV) lower port to thetransmission pump.

2 Place the machine safely onto blocks so that all fourwheels are clear of the ground. Ensure that the machineis stable.

3 Start the engine and run at max. revs. then select drive.Observe the reading on the pressure gauge then, usingthe graph below, plot a vertical line from the pressurereading and check that the flow recorded on theflowmeter is within the service limits set on the graph forthat pressure.

4 If the flow is outside the service limits suspect excessiveleakage within the hydrostatic system. Check that thehydraulic filter element is not blocked causing the by-pass valve to open.

Note: The transmission pump charge pressure relief valvemust be disabled (see description on page E/3-5). On servomachines screw adjustment in fully; on manual machines thevalve is shimmed and cannot be adjusted.

5 Lower the machine to the ground and repeat test inparagraph 3 whilst driving the machine against a solidimmovable object.

6 If the flow is outside the service limits suspect excessiveleakage within the motors.

7 Operate a loader service and check that the priority linepressure is not affected.

8 If the priority line pressure is below 16 bar (232 lb/in2; 16kg/cm2) or the pressure is affected by loader operationthe CPPV or the gear pump could be faulty. To checkwhich unit is faulty proceed as follows.

9 Connect a flow meter and load valve into the non-priorityline from the CPPV upper port to the valve block.Alternatively the flow meter and load valve can beconnected across the quick release couplings.

Note: The machine must remain static during the followingtests. If the transmission control levers are moved the motorflushing flow will increase and the non priority rate will drop.

10 With the load valve open and the engine at max. revs,the flow reading should be above 71 litres/min (15.6 UKgal/min; 18.8 US gal/min). If the flow reading is belowthis figure the gear pump is faulty.

11 Using the load valve, gradually increase the pressure inthe non-priority line. The flow and pressure readingsshould be as indicated in the table below.DO NOT EXCEED 150 Bar (2175 lb/in2, 153 kg/cm2).


9803/8520

Section E11 - 4

Issue 1


25

20

15

102 19 38

Litres/Min

Bar

0.5 5 10US gal/min

OptimumPressure

ServiceLimit

9 28

2.4 7.4

340270

Table of Non-priority flow/Pressure

Pressure Flowbar lb/in2 kg/cm2 l/min UK gal/min US gal/min

50 725 51 65 14.0 17.080 1160 82 61 13.5 16.0

100 1450 102 59 13.0 15.5120 1740 122 57 12.5 15.0140 2030 143 54 12.0 14.2150 2175 153 53 11.5 14.0

Charge Pressure Priority Valve Flow/Pressure Check (High-flow machines only)

11 - 5

Bleeding the Hydraulic System

It may be necessary to bleed the hydraulic system if majorcomponents have been removed. Air in the system will resultin uneven loader operation.

1 Make up a hose loop with two quick release connectorsand connect across the two standard quick releasecouplings A on the machine.

2 On High-flow machines connect a loop across the twolarge quick release couplings B on the boom.

3 Start the engine and warm the hydraulic oil to normaloperating temperature.

4 Stop the engine. Remove the hydraulic tank filler cap.Remove the seat and seat base.

5 Slacken hose connections at C (manual pump) and D(servo pump).

6 Start the engine and operate all loader and auxiliaryservices until all air is expelled from the loosenedconnections and oil flows freely.

7 Stop the engine and retighten connections C or D.

8 Remove the temporary loops from the quick releasecouplings and refit the hydraulic filler cap.


9803/8520

Section E11 - 5

Issue 1


341860

BA

AC

BD

324241 324880A

C

D

CONTENTS12 - 1


9803/8520

Section E12 - 1

Issue 1

Problem Solving

Levelling CircuitPROBLEM PROBABLE CAUSE REMEDY

1 Boom delay at start of self-level A Air in system A Cycle boom and bucket slowlyor unstable self-level to rid system of air

2 Loaded bucket dumps or raises A Unloading spool is leaking A Remove and inspect unloadingwhen control valve is in neutral spool for damage

3 Insufficient self-level A Pin X is out of adjustment A Re-adjust pin to achieve properflow split

B Broken unloading spool spring B Replace unloading spool spring

C Flow divider spool stuck C Remove flow divider spool andtowards port B check for damage

4 Bucket dumps faster than boom A Pin X out of adjustment A Re-adjust pin to achieve properraises. Too much self-level flow split

B Flow divider spool stuck B Remove flow divider spool andtowards port B check for damage

C Flow divider spool installed C Remove spool and install withincorrectly internal orifice towards port B

5 With bucket dumped, boom is A Dampening orifice in the A Remove unloading spool andslow in starting to raise unloading spool is blocked clean dampening orifice

6 Bucket does not move in self-level A Pin X is screwed in all the way A Re-adjust pin to achieve properflow split

B Dampening orifice in the B Remove unloading spool andunloading spool is blocked clean dampening orifice

C Ports A and B cross connected C Reverse hoses to ports A and B

7 Bucket raises in self-level A Ports A and B cross connected A Reverse hoses to ports A and B

8 External leakage A Damaged O ring A Replace O ring

X

21 - 1

Main Relief Valve (M.R.V.)Remove the seat and seat base.

Connect a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)pressure gauge to test connector A located on the right-handend of the loader valve block.

With the engine running at maximum speed, check theM.R.V. setting by raising or lowering the loader arm until therams are fully open or closed and noting the maximum gaugereading. Keep clear of the loader arm. The maximumpressure should be as stated in Technical Data.

If the pressure is incorrect, remove cap B from the M.R.V.and turn adjusting screw C clockwise to increase pressure oranti-clockwise to decrease the pressure. When the pressureis correct, refit cap B.

Remove the pressure gauge and refit the seat and seat base.


9803/8520

Section E21 - 1

Issue 1

Pressure Testing

333240

A

BC

CONTENTS

24 - 1

Pump/Engine Coupling

This is a gear type flexible coupling comprising an outercoupling B, bolted to the engine drive plate, and an innercoupling A clamped to the input shaft of the pump unit. Bothare contained within casing C, to which the pump unit isbolted.

The outer coupling B is bolted to the engine with fourcapscrews E. The inner section A is tightened onto the pumpshaft spline with cap screw D.

Coat threads of capscrew D with JCB Threadlocker andSealer and torque tighten to 49 Nm (36 lbf ft, 5 kgf m).

Coat threads of capscrews E with JCB Threadlocker andSealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).


9803/8520

Section E24 - 1

Issue 2

Pumps

AC

BD

324411

324430

CONTENTS

25 - 2


9803/8520

Section E25 - 2

Issue 2

Pumps

AC

BD

324221

HG

B

DDC

A

J

F

K

L

332881

YXZ

E

CONTENTS

25 - 3

Manual Pump - Return to Idle Controls

Removal and Replacement

Slacken locknut E. Slacken all three locknuts D just sufficientto release rod F from bracket L.

Lift clear the side plate assembly J, complete with blocks A,B, spring and retainer C and rod F.

Take care to retain the dowelled bracket K which may remainin its location in the bell housing or come away with the sideplate.

Replacement is the reverse of Removal, making sure that therod F is located through bracket K and into the bell housing.Also make sure that nuts D are correctly located either sideof bracket L.

Carry out the following adjustment procedure.

Adjustment

If the machine continues to move when neutral is selectedand also if the installation has been disturbed, the manualcontrols should be adjusted as detailed below.

! WARNINGThe following procedure requires the machine to bedisabled (wheels raised off the ground, work functiondisconnected etc.) while the work is carried out.HYD 8-1/1

Place the machine safely onto blocks so that all four wheelsare clear of the ground. Ensure that the machine is stable.

Stop the engine and remove both left wheels. Remove theseat.

Release the bolts securing the adjustment blocks A and Band slide the blocks away from the control lever rollers.Check for free movement of the control linkage, lubricate ifnecessary.

Release locknuts D and E and screw rod F fully into theengine bell housing.

Start the engine and allow to idle.

Lower the safety restraint to release the parking brake.

Position the L.H. drive control joystick in neutral so that thereis no movement of the left road wheels. Hold the lever in thisposition then slide adjustment block B in its grooves until itjust contacts the rollers on the control lever G. Keep a lightpressure on side plate J against spring C during this process.Tighten the securing bolts for block B.

Repeat the procedure for the R.H. lever and position andtighten adjustment block A against the rollers on lever H.

Screw guide rod F out of the bell housing to compress springC to a length of 70 mm (2.75 in). Tighten locknut E makingsure that the dowelled bracket K is correctly located into theside plate J and into the engine bell housing.

Tighten locknuts D ensuring that no load is applied to thebracket.

Operate both drive control joysticks in forward and reverse.Check for free movement of the linkage and that no wheelmovement occurs when the joysticks return to neutral.Repeat adjustment procedure if necessary.

Stop the engine. Refit the left road wheels and the seat andlower the machine to the ground.

Adjusting the Lever Stops for Straight Line Travel

If the machine does not travel in a straight line with bothlevers pushed fully forward, the control lever stops may beadjusted.

Caution: Stop the engine and remove the starter key whilstthe adjustment is made.

If the machine is veering to the right, slacken locknut X forthe left hand control lever and screw out (anti-clockwise) stopbolt Y one flat at a time. Re-tighten the locknut. Start theengine and check if the machine now travels in a straightline. If not repeat the adjustment.

If the machine veers to the left, carry out the adjustmentprocedure on the right hand control lever stop Z.


9803/8520

Section E25 - 3

Issue 1

Pumps CONTENTS

26 - 3


9803/8520

Section E26 - 3

Issue 1

Pumps

168030

CONTENTS

*26 - 4

Manual Pump - End Caps

Dismantling and Assembly

The numerical sequence shown on the illustration is intendedas a guide to dismantling.

For assembly the sequence should be reversed.

Note: The illustration shows a typical pump and is alsoshown upside down in this view.

Each end cap 8, 9 is secured to its pump by four capscrews1. Before dismantling, matchmark each end cap to its pump.Note that 'O' rings 3, 4 and 5 are only fitted to the rear pumpend cap 8. Locating dowels 6 need only be removed ifdamaged.

Note that shims 15 should be retained as a set. Onreassembly, use new 'O' rings and bearings.

Torque tighten bolts 1 to 47 - 61 Nm (4.8 - 6.2 kgf m, 35 - 45lbf ft).

Torque tighten plug 14 to 54 - 135 Nm (40 - 100 lbf ft, 5.5 -14 kgf m).

Charge Pressure Relief Valve

Checking and adjustment

If the charge pressure relief valve has been dismantled it willrequire setting up as follows:

1 Install a 0 - 40 bar (0 - 600 lb/in2, 0 - 42 kg/cm2) pressuregauge in the pressure test point X1 at the hydraulic filter.

2 Start the engine and warm the hydraulic oil to its normaloperating temperature.

3 Run the engine at maximum revs. and check thepressure at the gauge which should be as quoted inTechnical Data.

4 If the pressure is not correct, slacken locknut 13 andadjust screw 12 quarter of a turn at a time, clockwise toincrease pressure, anti-clockwise to decrease.

Note: On High-flow machines the charge pressure iscontrolled by the Charge Pressure Priority Valve (CPPV). Forthese machines the pump mounted charge pressure reliefvalve is set by means of shims and is not adjustable.


9803/8520

Section E26 - 4

Issue 2*

Pumps

326680

X1

*

CONTENTS

29 - 3


9803/8520

Section E29 - 3

Issue 1

Pumps

12

3 4

5

6

7

8

9

10

11

1213

14

15

16

17

18

19

20

337440

CONTENTS

29 - 4

Servo Pump

Charge/Anti-stall Valve

Dismantling and Assembly

1 Mark the plug 17, locknut 16 and the pump body so asto approximately maintain the original adjustment.

2 Loosen locknut 16 and unscrew plug 17 from pumpbody. Remove O ring 18 and discard.

3 Remove spring 19 and poppet 20 from pump body.

4 Inspect poppet 20 and mating seat in pump body fordamage. Renew as necessary.

5 Install a new O ring 18 on plug 17.

6 Fit poppet 20 and spring 19 into pump body.

7 Screw plug 17 complete with locknut 16 into pump bodyto align with the marks made during disassembly.Tighten the locknut.

8 Check the charge pressure and adjust as necessary.

Charge Pressure Checking and Adjustment

1 Stop engine. Connect a 0 - 40 bar (0 - 600 lb/in2, 0 - 42kg/cm2) pressure gauge into test point X1 at thehydraulic filter.

2 Start engine and check pressure is as specified inTechnical Data.

3 If the pressure is not as specified, stop the engine.Unscrew locknut 16 and turn adjuster 17 quarter of aturn at a time (clockwise to increase pressure) then re-tighten locknut. Start engine and re-check pressure.Continue procedure until pressure is correct thenremove pressure gauge.

Note: On High-flow machines the charge pressure iscontrolled by the Charge Pressure Priority Valve (CPPV). Forthese machines the pump mounted charge pressure reliefvalve should be disabled by screwing the adjustment screwin fully.


9803/8520

Section E29 - 4

Issue 1

Pumps

326680

X1

CONTENTS

36 - 1


9803/8520

Section E36 - 1

Issue 1

Motors

1

2

%

@

^

4

3

5

67

8

9

0

!

@

X

C

B

D

E&

)

(

&

4

5

6

7

8

A67

$

31

*

2

F

Y

Z

333700

333740

333720

333710

CONTENTS

36 - 2

With the seal grooves in flange 2 facing upwards, installseals and back-up rings 4 to 8 as shown at F. Make sure thatthese seals and seal 14 are securely held using petroleumjelly.

Position rotor 13 with splined side facing upwards as shown.

Align all match marks made before dismantling.

Note: The shuttle flow hole A on the underside of flange 2and holes B, C, D and E must all be aligned. Do not confusehole A with case drain hole X.

Make sure that check balls 12 are fitted in the seats in rotor13.

When inverting and fitting flange 2, make sure that the sealsare not dislodged.

Lubricate cap screws 1 with hydraulic fluid before fitting.Tighten to stage 1 torque setting in the sequence 1 to 9 asillustrated. Tighten to stage 2 torque following the samesequence.

Torque Settings

Item Nm kgf m lbf ft1 (stage 1) 61-75 6.2-7.6 45-551 (stage 2) 75-88 7.6-8.9 55-6519 23-29 2.3-2.9 17-2123 37-45 3.7-4.5 27-33


9803/8520

Section E36 - 2

Issue 1

Motors

Drive Motor

Dismantling

CAUTION: Do not pick up the motor by the drive shaft 11 asthis can cause damage to the balance plate 9.

Drain oil from motor. Make sure that the work area and theexterior of the motor are clean before starting dismantling.

Match mark items 2, 9,13, 15 and 17 to assist re-assembly.

Dismantle the motor in a vertical position as shown, followingthe numerical sequence.

Take care not to lose ball checks 12.

Keep parts of rotor assembly 13 together as they are closelymatched during manufacture. If they are dropped, carefullyremove minor damage using a fine abrasive stone.

Renew all parts where the mating surfaces have deepscratches or burrs which will not easily polish out.

Wash all metal parts in clean solvent and blow dry usingcompressed air. Do not use paper towels or cloth as lint inthe hydraulic system will cause damage.

Inspection

Item 11:Check seal diameter for excessive wear.

Item 13:a) Check pockets for any signs of excessive wear from

roller contact.b) Check star profile for any excessive or irregular wear.c) Check internal splines for any sign of excessive wear.

Spline teeth should not show any signs of spalling orchipping.

d) Check outer diameter of rollers for any sign ofexcessive wear or spalling.

Item 15: Check mating surface with item 13 for any unusual wearmarks.

Assembly

Reverse the dismantling sequence with the followingexceptions.

Renew all seals, using petroleum jelly as a lubricant and tohold them in position.

Lubricate machined surfaces with clean hydraulic fluid.

Install poppet 30, spring 29 and dash pot 28 into shuttle valvebore from valve plate side of end cap 17. Install shuttle piston31 from opposite side (position Y), followed by the otherpoppet 27, spring 26 and dash pot 25. Fit O ring 24 and plug23, tightened to specified torque setting.

Install poppet 22, spring 21, O ring 20 and plug 19 atposition Z.. Tighten plug to specified torque setting.

333750

CONTENTS

40 - 2


9803/8500

Section E40 - 2

Issue 1

Valves CONTENTS

24

29

1716

13

4

7

3

8910

6

12

1112

5

14 15

181920

21

2223

25262728

3b

77d 7c

7b7a

3a

3c

3d

3f

3e

337410

CONTENTS

Assembly

Assembly is a reversal of the dismantling procedure.

Renew all seals and 'O' rings.

Lubricate all parts with hydraulic oil before assembly.

If the spools have been dismantled, apply 2 or 3 drops ofJCB Threadlocker & Sealer to threads of shoulder bolt 7aafter degreasing threads.

Ensure that the spools are inserted in their correct bores.

If guide 3f has been removed, assemble using JCB HighStrength Threadlocker and ensure that grooves X arepositioned at right angles to the centre line of the spool asshown. Press the guide into position. Do not use a hammerotherwise the body could be damaged.

Check operation of lock-out solenoid 3 after assembly. Withthe solenoid de-energised the spool should be locked in theneutral position. Connect a 12 volt electrical supply to thesolenoid and check for free spool operation. Carry out checkthree times to confirm correct operation.

40 - 3

Loader Valve - Servo Machines

Dismantling

A seal kit may be purchased from JCB Service and thisshould be available before commencing work. Always workon a clean, dirt free surface.

1 Remove cap screws 1 and remove servo cylinder 2.(These are fitted to both main spools.)

2 Unscrew and remove spool lock solenoids 3 frommounting blocks 6 (one on each main spool). If requiredthe solenoid assembly may be dismantled further forcleaning as shown in the inset. Solenoid 3b may berenewed separately. It should not normally be necessaryto remove guide 3f as it is an interference fit in body 6and is also secured with locking fluid.

3 Remove cap screws 4 and remove servo cylinders 5 andmounting blocks 6 from both main spools.

4 Carefully withdraw each main spool assembly 7.Remove and discard O rings 8, 9 and 12 and wiperseals 10 and 11.

5 Remove capscrews 13 and seal retainer 14 fromauxiliary spool if fitted.

6 Remove capscrews 16 and housing 17. Carefullywithdraw auxiliary spool 18. Remove and discard Orings 19, 20 and 23 and wiper seals 21 and 22.

The spools may be dismantled further if required asshown in the inset. Note that shoulder bolt 7a is securedwith locking fluid.

Note: Work on the spools individually. Return each spool toits original bore. Do not interchange parts from individualspools.

7 Remove main relief valve 24.

8 Remove each check valve guide 25, spring 27 andpoppet 28. Discard O ring 26.

9 It should not normally be necessary to remove restrictor29.

10 Clean all parts in kerosene, inspect and check fordamage.


9803/8520

Section E40 - 3

Issue 1

Valves

3a

3c

3b

3d

3f

6

3f X

X 337420

41 - 2


9803/8500

Section E41 - 2

Issue 1

Valves CONTENTS

19

24

6

12

2021

5

1 23 17

18

7

4

11

131415

16

8910

2223

4b

77d 7c

7b7a

4a

4c

4d

4f

4e

337400

41 - 3

Loader Valve - Manual Machines

Dismantling

A seal kit may be purchased from JCB Service and thisshould be available before commencing work. Always workon a clean, dirt free surface.

1 Remove cap screws 1 and remove seal retainer 2 andseal 3 from each spool.

2 Unscrew and remove spool lock solenoids 4 frommounting blocks 6 (one on each main spool). If requiredthe solenoid assembly may be dismantled further forcleaning as shown in the inset. Solenoid 4b may berenewed separately. It should not normally be necessaryto remove guide 4f as it is an interference fit in body 6and is also secured with locking fluid.

3 Remove cap screws 5 and remove mounting blocks 6from both main spools.

4 Carefully withdraw each main spool assembly 7.Remove and discard O rings 8, 9 and 18 and wiperseals 10 and 17.

5 Remove capscrews 11 and housing 12. Carefullywithdraw auxiliary spool 13. Remove and discard Orings 14, 15 and 18 and wiper seals 16 and 17.

The spools may be dismantled further if required asshown in the inset. Note that shoulder bolt 7a is securedwith locking fluid.

Note: Work on the spools individually. Return each spool toits original bore. Do not interchange parts from individualspools.

6 Remove main relief valve 19.

7 Remove each check valve guide 20, spring 22 andpoppet 23. Discard O ring 21.

8 It should not normally be necessary to remove restrictor24.

9 Clean all parts in kerosene, inspect and check fordamage.

Assembly

Assembly is a reversal of the dismantling procedure.

Renew all seals and 'O' rings.

Lubricate all parts with hydraulic oil before assembly.

If the spools have been dismantled, apply 2 or 3 drops ofJCB Threadlocker & Sealer to threads of shoulder bolt 7aafter degreasing threads.

Ensure that the spools are inserted in their correct bores.

If guide 4f has been removed, assemble using JCB HighStrength Threadlocker and ensure that grooves X arepositioned at right angles to the centre line of the spool asshown. Press the guide into position. Do not use a hammerotherwise the body could be damaged.

Check operation of lock-out solenoids 4 after assembly. Withthe solenoid de-energised the spool should be locked in theneutral position. Connect a 12 volt electrical supply to thesolenoid and check for free spool operation. Carry out checkthree times to confirm correct operation.


9803/8520

Section E41 - 3

Issue 1

Valves CONTENTS

4a

4c

4b

4d

4f

6

4f X

X 337420

50 - 3


9803/8520

Section E50 - 3

Issue 1

Servo Joysticks

337460

CONTENTS

50 - 4

Dismantling

Lift up the gaiter 1, release locknut 2 and remove the handleassembly 3. If necessary slacken capscrew 4 and clamp 5 torelease the electrical cable.

Unscrew nut 6 and remove actuator plate 7. Removecapscrew 4 with clamp 5, remove three capscrews 8 then liftoff plates 7 and 10 from the valve body 17.

Carefully remove gland seal assembly 11 from each bore.Remove and discard O ring 12. Carefully withdraw eachvalve unit 13 from its bore.

Note: Ensure that the components of valve units 13 andgland seals 11 are kept together as sets and returned to theiroriginal locations in the body. Do not mix components fromdifferent valve units.

If necessary, remove adapters 14 and discard O rings 15and 16. Note on the transmission joystick the position of theextended adapters.

Assembly

Lubricate all parts with hydraulic fluid before assembly.Renew all 'O' rings and seals, lightly coating with vaselineprior to assembly.

Ensure that valve units 13 and gland seals 11 are located inthe bores from which they were originally removed (see noteopposite).

Assemble plates 10 and 9 and secure with capscrews 8 and4. Tighten to 12 Nm (9 lbf ft).

Assemble actuator plate and tighten nut 6 so that actuatorplate just touches the plungers in gland seals 11.

Assemble handle 3 and, after positioning correctly, tightenlocknut 2. If necessary, secure electrical cable under clamp5.

If disturbed, replace adapters 14 using new O rings andnoting the posit ion of the extended adapters on thetransmission joystick.


9803/8520

Section E50 - 4

Issue 1

Servo Joysticks CONTENTS

61 - 1

Suction Strainer

! WARNINGMake the machine safe before working on it. Park themachine on level ground and lower the loader arm. Stopthe engine and remove the starter key. Make sure theparking brake is engaged. Disconnect the battery, toprevent the engine being started. Chock all four wheels.3-3-1-2

Note: The hydraulic tank is shown removed from themachine for clarity.

Removal and Replacement

1 Drain the hydraulic tank. Access to the hydraulic tankdrain plug is through the chassis blanking plate X.Remove the blanking plate and place a suitablecontainer beneath the machine to catch the oil.

Note: There are three drain plugs located behind theblanking plate. The hydraulic oil drain is coloured black.

2 Remove the suction hose from the stub pipe A.

3 Unscrew bolts B, remove cover plate C together with itsgasket D.

4 Unscrew and remove the suction strainer E. Wash in asuitable solvent and allow to dry.

Note: A new strainer should be similarly washed beforefitting, to remove the protective coating.

5 Reassemble in reverse order using a new gasket.Tighten bolts B to 28 Nm (20 lbf ft; 3 kgf m). Refit thesuction hose.

6 Refill the tank with the correct fluid (see page 3/1 - 1).


9803/8520

Section E61 - 1

Issue 1

Hydraulic Tank

D

C

A

B

E

X338460

CONTENTS

3 - 2

Section F Transmission

9803/8520

Section F3 - 2

Issue 1

Hubs and Driveshafts CONTENTS

12

5

87

13

64

2

31

9

11

10

5 5

8 7

1313

64

4

23

1

327500

YX

3 - 3

Wheel Hub Assembly (right hand)Dismantling

Remove bolt 1, plain washer 2 and retainer 3. Remove drivesprocket 4.

Support the casing assembly on its outer flange with thewheel hub facing downwards and press out the axle shaftassembly 5. Bearing 6 will remain in the casing 13 and canbe removed separately if necessary. The outer race ofbearing 7 will also be left in the casing and can be removed ifnecessary. Shaft seal 8 should be removed and discarded.

If necessary, remove bolts 9 with washers 10 and removetwine cutter 11.

Inspection

Thoroughly clean and dry all components. Examine thebearings, axle shaft and casing for wear or damage. Renewas necessary.

Assembly

Assemble the twine cutter, if previously removed, and tightenbolts 9 to the correct torque.

Lubricate all bearings and seals with JCB Special HP Greasebefore assembly.

Press bearing 7 into casing 13 ensuring that the outer race ispressed fully home.

Assemble outer race of bearing 6 into casing 13. Ensure it ispressed fully home.

Fit the two halves of the oil seal installer A (825/10003)around the axle shaft 5 and position a new oil seal 8, with theseal lip facing inwards, against the installer. Feed axle shaft 5into the casing.

Assemble the inner race of bearing 6 onto axle shaft 5 andslide sprocket 4 onto the splines of the axle shaft.

Note: The front sprocket should be assembled with its bosstowards the casing, as at X. The rear sprocket should beassembled with its boss away from the casing, as at Y.

Screw threaded stud C of assembly tool B (825/10002) fullyinto the end of the axle shaft as shown then continue turningthe stud to pull the axle shaft into the casing so that the oilseal is fully installed. Release the assembly tool and removethe oil seal installer. Note that it may be necessary to gentlytap the end of the shaft to release the installer.

Reassemble tool B and continue pulling the axle shaft intoposition by tightening stud C to preload the bearings. Rotatethe shaft during this process to seat the bearings.

Fit a torque meter to the head of stud C and check the torquerequired to rotate the axle shaft. The correct rolling torqueshould be 80 Nm (59 lbf ft, 8.2 kgf m). Continue tighteningstud C until the correct rolling torque is acheived.

Position a dial gauge against the flat face of the sprocket asshown at D and zero the gauge. Reposition the dial gaugeonto the end of the axle shaft as shown at E and note thereading. Remove the gauge and assembly tool.

Retainer 3 is available in three thicknesses to allow for thecorrect preload of bearings 6 and 7. The retainers can beidentified as follows:

Colour Preload dimensionSelf colour 0.01 - 0.085 mm (0.0004 - 0.0033 in)Yellow 0.09 - 0.165 mm (0.0035 - 0.0065 in)Black 0.17 - 0.25 mm (0.0067 - 0.0098 in)

Select the retainer which gives the closest match to the dialgauge reading and assemble onto the axle shaft. Fit washer2 and bolt 1. Tighten bolt 1 to the correct torque whilstrotating the shaft to seat the bearings.

Fit a torque meter to the head of bolt 1 and check the rollingtorque is still 80 Nm (59 lbf ft, 8.2 kgf m).

Torque Settings

Item Nm lbf ft kgf m1 225 166 239 28 21 3


9803/8520

Section F3 - 3

Issue 1


333181

A

A

B

D

E333191

C

4 - 1


9803/8520

Section F4 - 1

Issue 1


1514

12

109

4

8

11

3

1312

67

4

9

4

91

2 3

8

8 10 11

5

327511

Y

X

4 - 2

Drive Shaft Assembly (left hand)Dismantling

It is assumed that roadwheels are removed and the machineis correctly supported.

Drain the oil from the chain case (see Drive ChainLubrication, Section 3).

Remove the appropriate right hand hub assembly to gainaccess to the shaft retaining bolt (see Wheel HubAssembly, this section).

Remove the seat base. Slacken the nuts securing the uppermotor mounting to the chain case. Screw in the adjustmentbolts to lower the mounting and thus slacken the drive chains(see Drive Chain Adjustment, this section).

Remove bolt 1, plain washer 2 and retainer 3. Remove drivesprocket 4. Remove spring clip 5 and withdraw oil scraper 6and spring 7 from inside the chain case.

Drift the axle shaft 8 out of the axle tube. Bearing 9 willremain in the axle tube and can be removed separately ifnecessary. The outer race of bearing 10 will also be left inthe axle tube and can be removed if necessary. Shaft seal 11should be removed and discarded.

If necessary, remove bolts 12 with washers 13 and removetwine cutter 14.

Inspection

Thoroughly clean and dry all components. Examine thebearings and axle shaft for wear or damage. Renew asnecessary. Examine axle tube for wear of the bearing bores.

Check oil scraper for wear, renew as necessary. Check thatoil holes in scraper, and in axle tube, are clear.

Assembly

Assemble the twine cutter, if previously removed, and tightenbolts 12 to the correct torque.

Lubricate all bearings and seals with JCB Special HP Greasebefore assembly.

Press outer bearing 10 into axle tube ensuring that the outerrace is pressed fully home.

Assemble outer race of inner bearing 9 into axle tube. Ensureit is pressed fully home.

Fit the two halves of the oil seal installer A (825/10003)around the axle shaft 8 and position a new oil seal 11, withthe seal lip facing inwards, against the installer. Slide axleshaft 8 into the axle tube.

Fit oil scraper 6 with its spring 7 onto the dowels protrudingfrom the inner face of the chaincase and secure with springclip 5. Check that the scraper slides freely on the dowels.

Note: The short oil scraper fits against the front sprocket.The long oil scraper fits against the rear sprocket.

Assemble the inner race of bearing 9 onto axle shaft 8 andslide the sprocket 4 onto the splines of the axle shaft.

Note: The front sprocket should be assembled with its bossaway from the axle tube, as at X. The rear sprocket shouldbe assembled with its boss towards the axle tube, as at Y.


9803/8520

Section F4 - 2

Issue 1


333201

AB

A

4 - 3

Assembly (continued)

Screw threaded stud C of assembly tool B (825/10002) fullyinto the end of the axle shaft as shown then continue turningto pull the axle shaft into the axle tube so that the oil seal isfully installed. Release the assembly tool and remove the oilseal installer. Note that it may be necessary to gently tap theend of the shaft to release the installer.

Reassemble tool B and continue pulling the axle shaft intoposition by tightening stud C to preload the bearings. Rotatethe shaft during this process to seat the bearings.

Fit a torque meter to the head of stud C and check the torquerequired to rotate the axle shaft. The correct rolling torqueshould be 80 Nm (59 lbf ft, 8.2 kgf m). Continue tighteningstud C until the correct rolling torque is acheived.

Position a dial gauge against the flat face of the sprocket asshown at D and zero the gauge. Reposition the dial gaugeonto the end of the axle shaft as shown at E and note thereading. Remove the gauge and assembly tool.

Retainer 3 is available in three thicknesses to allow for thecorrect preload of bearings 9 and 10. The retainers can beidentified as follows:

Colour Preload dimensionSelf colour 0.01 - 0.085 mm (0.0004 - 0.0033 in)Yellow 0.09 - 0.165 mm (0.0035 - 0.0065 in)Black 0.17 - 0.25 mm (0.0067 - 0.0098 in)

Select the retainer which gives the closest match to the dialgauge reading and assemble onto the axle shaft. Fit washer2 and bolt 1. Tighten bolt 1 to the correct torque whilstrotating the shaft to seat the bearings.

Fit a torque meter to the head of bolt 1 and check the rollingtorque is still 80 Nm (59 lbf ft, 8.2 kgf m).

Refit and adjust the chains (see Drive Chain Adjustment,this section).

Refit the right hand wheel hub assembly (see Wheel HubAssembly, this section).

Refit the chaincase access cover using a new gasket. Refillthe chain case with the correct oil.

Torque Settings

Item Nm lbf ft kgf m1 225 166 2312 28 21 3


9803/8520

Section F4 - 3

Issue 1


333211E

D

C

5 - 2

AdjustmentNote: The drive chains are pre-tensioned during manufactureand do not require routine adjustment in service. Thefollowing procedure should be carried out whenever thechains are disturbed or renewed.

Left Hand Chain Adjustment

Adjust as follows:

1 Drain the oil from the chaincase.

2 Remove the seat and pump cover. Remove thechaincase access cover D.

3 Slacken the four bolts A securing the upper motormounting to the chaincase.

4 Slacken locknuts B and tighten or loosen bolts C to raiseor lower the mounting. Rotate the sprocket so that oneside of the chain is taut. Position the motor mounting togive 25 mm (1 in) of slack on the opposite side of thechain at the midway point.

5 When the correct adjustment is achieved, tightenlocknuts B. Tighten the upper motor mounting bolts A.

6 Refit the chaincase access cover D using a new gasket.Refill the chaincase with the correct oil.

7 Refit the seat and floorplate.

Right Hand Chain Adjustment

Adjust as follows:

1 Drain the oil from the chaincase.

2 Remove the chaincase access cover D.

3 The hub mounting bolts E should be loosened and nut Ffinger tight only.

4 Slacken locknut G and screw adjustment bolt H out topush the hub away from the centre of the machine andso tighten the chain.

5 Rotate the sprocket so that one side of the chain is taut.Position the hub to give 25 mm (1 in) of slack on theopposite side of the chain at the midway point.

6 When the correct tension is achieved, tighten bolts E andnut F. Tighten the second locknut to the adjustment boltH.

7 Torque tighten nut F and bolts E to 244 Nm (180 lbf ft,25 kgf m).

8 Refit the chaincase access cover D using a new gasket.Refill the chaincase with the correct oil.


9803/8520

Section F5 - 2

Issue 1

Drive Chains

333140

B

C

A

333150

F

E

G

HD

CONTENTS

8 - 1

Hydraulic System

! WARNINGFine jets of hydraulic fluid at high pressure canpenetrate the skin. Do not use your fingers to check forhydraulic fluid leaks. Do not put your face close tosuspected leaks. Hold a piece of cardboard close tosuspected leaks and then inspect the cardboard forsigns of hydraulic fluid. If hydraulic fluid penetrates yourskin, get medical help immediately.INT-3-1-10/1

Checking the Fluid Level - for interval see ServiceSchedule

1 Lower the lift arm and fully crowd the shovel/ attachmentas shown at X. Stop the engine.

2 Look at the fluid level in the sight glass A. The levelshould be at the mark on the sight glass.

If the fluid in the sight glass appears cloudy, then wateror air has entered the system. The hydraulic pump couldbe severely damaged if the machine is operated.

3 If more fluid is needed, wait for five minutes, open thehydraulic tank filler cap B and top up with engine oil.

Changing the Filter - for interval see Service Schedule

1 Stop the engine and wait until the system has cooled.

2 Open the engine top cover.

3 Loosen the hydraulic tank filler cap B and allow allpressure to dissipate. Remove the filler cap.

4 Unscrew the old filter canister C, using a chain wrench ifnecessary, and discard.

5 Lubricate seal D on the new filter canister with cleanengine oil.

6 Screw on the new filter canister hand tight only.

Note: On machines fitted with the High Flow option a secondfilter is fitted behind the main filter. Repeat procedure forsecond filter.

7 Refit cap B, run the engine for a few minutes, then re-check the fluid level.

Note: Old filters should be disposed of in accordance withlocal Health and Safety regulations.

Section 3 Routine Maintenance

9803/8520

Section 38 - 1

Issue 2

CONTENTS

A BC

CD

323791

323780

X

9 - 2

Transmission

Tyres and Wheels

Inflating the Tyres

! WARNINGOver-inflated or overheated tyres can explode. Do notcut or weld the rims. Get a tyre/wheel specialist to doany repair work.5-3-2-4

These instructions are for adding air to a tyre which isalready inflated. If the tyre has lost all its air pressure, call ina qualified tyre mechanic. The tyre mechanic should use atyre inflation cage and the correct equipment to do the job.

1 Prepare the Wheel

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

2 Prepare the Equipment

Use only an air supply system which includes a pressureregulator. Set the regulator no higher than 1.38 bar (20lbf/in2, 1.4 kgf/cm2) above the recommended tyrepressure. See Table below.

Use an air hose fitted with a self-locking air chuck andremote shut-off valve.

3 Add the Air

Make sure that the air hose is correctly connected to thetyre valve. Clear other people from the area. Standbehind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do notover-inflate.

Tyre Pressure Table

Replacing Segments of Optional Non-Inflatable Tyres

Non-inflatable tyres are available as an option for use inenvironments where a puncture could have seriousconsequences. These tyres consist of a number of individualsegments bolted to the wheel rim.

Damaged segments can be renewed individually. Loosenand remove the four nuts and washers A (two each side ofthe wheel). Lift the segment clear by extracting its fixingstuds from the holes in the wheel rim.

Fit a new segment in reverse order to removal, then tightenthe retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).

Checking the Wheel Bolt Torques

On new machines, and whenever a wheel has beenremoved, check the wheel bolt torques every two hours untilthey stay correct.

Every day, before starting work, check that the wheel boltsare tight.

The correct torque is shown in the table below.

Front & Rear

Nm lbf ft kgf m244 180 25

! WARNINGIf, for whatever reason, a wheel bolt is renewed, all thebolts for that wheel must be changed as a set, since theremaining bolts may have been damaged.3-3-2-1

Section 3 Routine Maintenance

9803/8520

Section 39 - 2

Issue 1

CONTENTS

A

Make Size Pressure bar (lbf/in2)

Solideal 10 x 16.5 x 6Ply 3.1 (45)

Solideal 10 x 16.5 x 8Ply 4.2 (61)

Galaxy 10 x 16.5 x 8Ply 4.1 (60)

Solideal 700 x 15 x 6Ply 4.1 (60)

Solideal 700 x 15 x 14Ply 4.1 (60)

Galaxy 31.5/1300 x 16.5 x 10Ply 4.1 (60)

Documents

160-170 Mk3 ProbSolv