JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual

Section E

Hydraulics

Section E

88 - 2

Hydraulic Rams

88 - 2

Dismantling and Assembly

Assembly

- Power Sideshift Ram

Clean the threads of the end caps and cylinder using a

wire brush.

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

Use JCB Cleaner/Degreaser to ensure that all threads

are free from grease, hydraulic oil and sealant. Allow 15

For assembly the sequence should be reversed.

minutes for solvent to dry before applying JCB

Threadlocker and Sealer (High Strength).

Dismantling

Ensure that lubricants used during assembly do not

Fix the ram assembly on a locally manufactured

come into contact with the JCB Threadlocker and

strip/rebuild bench as shown at A.

Sealer (High Strength).

Remove both end caps 1, (46mm AF). Pull the piston

Refer to JCB Ram Sealing Procedure for the correct

rod assembly from the cylinder.

method of fitting seals to the end cap and piston head.

Note 1: DO NOT allow the piston rod to come into contact

Clamp the cylinder vertically and lower the piston rod

with the cylinder bore. The cylinder bore may be damaged

assembly in from the top, as shown at B. Take care not

by careless dismantling.

to allow the piston rod to come into contact with the

cylinder bore. Be sure to engage the piston head new

Position the piston rod assembly on a bench in place of

wear rings and seal carefully into the cylinder. If the

the ram cylinder. Remove the wear rings 2 and seal 3

piston head wear rings or seal are damaged during this

from the piston head.

stage, they must be renewed.

Note 2: The piston head cannot be removed from the rod. If

Fit new ‘O’ rings 8 to spacers 7, slide onto the piston

there is damage to the rod or piston head, replace the

head and rod assembly.

complete assembly.

Apply JCB Activator to threads of the end caps and

Carefully inspect the bore of the cylinder and the piston

cylinder. Allow Activator to dry for 15 minutes before

rod outer diameter for scoring, nicks and burrs. If such

bringing into contact with the JCB Threadlocker and

damage is visible the components must be renewed.

Sealer (High Strength).

Note 3: If burrs are evident on the ends of the piston rod at

Note 4: Neither the JCB Threadlocker and Sealer (High

positions C or D remove by careful filing.

Strength) nor Activator must be allowed to contact seals,

bearing rings or ‘O’ rings.

Remove the end cap seal 4, wiper seal 5 and ‘O’ ring 6,

both end caps are the same

Apply JCB Threadlocker and Sealer (High Strength) to

threads of the ends caps, fit new ‘O’ rings 6.

Remove spacers 7 and ‘O’ rings 8.

Ensure that there are no burrs at the ends of the piston

rod, see Dismantling - Note 3:

Fit an end cap over the piston rod. Apply light hand

pressure to the cap to engage the gland seal on the

piston rod. DO NOT use excessive force. Screw on the

first end cap and then fix the assembly on the

strip/rebuild bench as shown at A. Fit the remaining

cap and then torque tighten both caps.

Note

5: If hydraulic oil contacts the uncured JCB

Threadlocker and Sealer (High Strength) a weakening of the

bond will result. Cure times vary according to the ambient

temperature. Allow a minimum of

2 hours between

assembly and filling the ram with oil.

Torque Settings

Item

kgf m lbf ft

400

40.8

295

9803/3280

Issue 1

Section E

Hydraulics

Section E

89 - 1

Hydraulic Rams

89 - 1

JCB Ram Sealing Procedure

To fit new rod seal:

Use seal fitting tool (892/00334) to fit rod seals, the size

(diameter) and position of pins A is determined by the

diameter and radial width of the rod seal being fitted.

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.

Open the tool as shown at B and insert the new rod

seal, the seal must be fitted behind the two front pins

but in front of the rear pin as shown.

Note: Make sure the seals are fitted the correct way round,

as shown at P and Q.

161750

Close the tool as shown at C. The seal must form a

reniform (kidney shape).

Before fitting the rod seals check the seal grooves are

free of contamination and sharp edges,

Locate the seal in the end cap groove, shown at D,

when the seal is in position, open the tool to release the

seal. Make sure the seal is correctly installed in its

groove and remove the tool.

Fit rod wiper seal P into seal groove. Make sure the seal

is correctly installed as shown.

Note: Some rod wipers, ie power track rod, may use a metal

encased seal which is pressed into the housing. Care must

be taken to ensure the seal is square before it is pressed in.

153212

Sleeve E must be used to protect the rod seals from damage

when fitting end cap onto the piston rod. There are various

sizes of sleeve, see Service Tools. Make sure the hexagon

on the end cap is towards the eye end of the rod.

A187361

9803/3280

Issue 1

Section E

Hydraulics

Section E

89 - 2

Hydraulic Rams

89 - 2

JCB Ram Sealing Procedure (continued)

Fit new piston head seals:

Use a blunt instrument (892/01027) shown at F, lever

the inner seal G 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 the marks are

visible and the seal is free to rotate, if not remove the

seal and refit

Fit outer seal H using the same procedure as step 6.

Check the external grooves are visible.

Ensure O ring is fitted into the internal seal groove on

the piston head. Screw the piston head onto the thread

338470

of the piston rod, refer to the relevant section for torque

figure and completion of ram assembly.

Fit the piston head retaining dowel, see ram dismantling

and assembling relevant section

Fit wear rings J and K. Rotate the wear rings so that the

piston retention dowel is covered by the wear ring, NOT

as shown at L.

Fit the piston rod and head assembly into the cylinder:

Insert the piston/rod assembly into the cylinder. Align

the rod and head assembly until parallel with the

cylinder then push the assembly into the cylinder.

Fit the end cap, refer to the relevant section for torque

338480

figure and completion of ram assembly.

338490

9803/3280

Issue 1

Section E

Hydraulics

Section E

95 - 1

Hydraulic Oil Cooler

95 - 1

Removal and Replacement

! WARNING

Replacement

Raised loader arms can drop suddenly and cause serious

injury. Before working under raised loader arms, fit the

Replacement is a reversal of the removal sequence.

loader arm safety strut.

GEN 3-2

! WARNING

! DANGER

Fine jets of hydraulic fluid at high pressure can

Hydraulic Pressure

penetrate the skin. Do not use your fingers to check for

Hydraulic fluid at system pressure can injure you. Before

hydraulic fluid leaks. Do not put your face close to

disconnecting or connecting hydraulic hoses, stop the

suspected leaks. Hold a piece of cardboard close to

engine and operate the controls to release pressure

suspected leaks and then inspect the cardboard for

trapped in the hoses. Make sure the engine cannot be

signs of hydraulic fluid. If hydraulic fluid penetrates your

started while the hoses are open.

skin, get medical help immediately.

INT-3-1-11/1

INT-3-1-10/1

Removal

When installing and removing hoses from the cooler, it is

essential to note that adaptor C must be held with a

Park the machine on firm level ground, engage the

spanner whilst installing or removing the hose. Tighten hose

parking brake and set the transmission to neutral.

connections to a torque of 58 Nm (42 lbf ft).

Lower the backhoe and loader end to the ground and

stop the engine.

Vent residual hydraulic pressure by operating the

controls back and forth several times.

Label and then remove hydraulic hoses A and B (see

note). Plug and cap all open ports to prevent loss of

fluid and ingress of dirt.

Note: When installing and removing hoses from the cooler, it

is essential to note that adaptor C must be held with a

spanner whilst installing or removing the hose. It may be

easier to remove the top hose connection once the cooler

has been removed from the machine (disconnect top hose at

connection D).

Loosen and remove cooler mounting bolts E (4 off) and

remove the cooler F.

A401100

9803/3280

Issue 1

Section E

Hydraulics

Section E

96 - 1

Smooth Ride System

96 - 1

Accumulator

Removal and Replacement

Removal

Replacement

Park the machine on level ground, lower the loader

Replacement is a reverse of removal.

arms, switch off the engine and chock all four wheels.

Release all hydraulic pressure in the accumulator by

Charge the accumulator, refer to Service Procedures,

selecting the SRS ON and operating the loader arm

Smooth Ride System - Charging/Discharging the

hydraulic lever.

Accumulator.

Operate the machines hydraulic system. Check for

! DANGER

correct operation and leaks.

Before disconnecting or dismantling the accumulator

discharge all gas pressure. Failure to comply can cause

Replenish the hydraulic system with the recommended

rapid discharge of gas and/or hydraulic fluid which can

hydraulic fluid as required, refer to Section 3 Fluids,

result in death, personal injury and damage to the

Lubricants, Capacities and Specifications.

machine.

Hyd 2-5

Discharge the accumulator, refer to Service

Procedures,

Smooth

Ride

System

Charging/Discharging the Accumulator.

Disconnect hydraulic hose A and plug.

Loosen both ‘U’ clamps B and slide the accumulator

towards the front of the machine. When clear of the ‘U’

clamps carefully lower and withdraw accumulator.

S308290

9803/3280

Issue 1

Section E

Hydraulics

Section E

96 - 3

Smooth Ride System

96 - 3

Accumulator

Dismantling and Assembly

Assembly

Dismantling

Coat all internal components with clean hydraulic oil.

! DANGER

Before disconnecting or dismantling the accumulator

Fit piston seal 9, teflon back up rings 10 and seals 11.

discharge all gas pressure. Failure to comply can cause

rapid discharge of gas and/or hydraulic fluid which can

Fit piston assembly into bore 1 with hollow side

result in death, personal injury and damage to the

towards the gas end. Do not let piston seal drag on

machine.

threads, the piston must go into the bore exactly

HYD 2-5

square and very slowly. The piston is a tight fit, use a

hammer and a block of wood to tap the piston until all

Check that the accumulator has been discharged, refer

of the piston is 2in. (50mm) below the beginning of

to Service Procedures, Smooth Ride System -

honed bore.

Charging/Discharging the Accumulator.

Note: Keep pressure on the piston while tapping through

Secure the accumulator in horizontal position.

the bore chamfer, otherwise the piston will bounce back,

damaging the piston ring.

! CAUTION

The gas end cap (cap with gas valve) must be removed

Fit end cap back up seal 7. Make sure the seal is fitted

before the hydraulic end cap. This allows any residual

with leading edge A pointing in a counter clockwise

pressure to escape through the safety vent holes. If the

direction otherwise the seal will bind when the end cap

hydraulic end cap is removed first the piston will cover

is fitted.

the safety vent holes, which could result in the piston

being forced out under pressure which may result in

Fit end cap ‘O’ rings 8, it is important that seals 7 and 8

personal injury.

are fitted in the correct position in relation to each other

HYD 2-6

to prevent leaks.

Fit three pins into the holes in gas end cap 4, using a

Fit end caps 4 and 5, use pins and a long bar. Make

long bar working against the pins unscrew the end cap.

sure the gas end cap is fitted to the correct end, piston

hollow end to gas side.

Fit three pins into the holes in hydraulic end cap 5,

using a long bar working against the pins unscrew the

Note: The end caps will stop against the chamfer leading

end cap.

into the honed bore, ‘O’ ring sealing is not dependent upon

cap tightness.

Remove and discard ‘O’ rings and back up rings from

end caps.

Use new ‘O’ ring 13 and fit the gas valve 12.

Remove the piston 6 by pushing from the hydraulic end

with a bar.

! CAUTION

Do not remove the piston by applying compressed air at

the opposite end.

HYD 2-7

Remove piston seal and ‘O’ rings.

Inspection

Inspect piston for cracks, burrs around the ‘O’ ring grooves,

or damage. Examine the body bore 1, using a light, for

scratches or scoring. Inspect end caps for damaged threads

or burrs on ‘O’ ring grooves.

Minor nicks, scratches or light scoring of the body bore may

be removed by using a very fine paper. Dress the bore until

all apparent imperfections have been removed.

All seals and ‘O’ rings must discarded and new ones fitted.

9803/3280

Issue 1

Section F

Transmission

Section F

Contents

Page No.

Service Tools

Technical Data

Wheels and Tyres

Axles

Synchro Shuttle Gearbox

Powershift Gearbox - 6 Speed

Powershift Gearbox - 4 Speed

Engine Stall Speed Combinations

Basic Operation

Axles

15 -

Synchro Shuttle Gearbox

Component Identification

16 -

Principle of Operation

16 -

Hydraulic and Electrical Operation

16 -

Powershift Gearbox

Component Identification

17 -

Principle of Operation

17 -

Hydraulic and Electrical Operation

17 -

ShiftMaster Operation Characteristics

17 -

Drive Paths - 4 Speed

18 -

Drive Paths - 6 Speed

18 -

Torque Converter

Component Identification

20 -

Principle of Operation

20 -

Systems Description

Synchro Shuttle Gearbox

Syncromesh (Blocking Pin Type)

25 -

Forward/Reverse Clutch Operation

26 -

2/4 Wheel Drive Clutch Operation

- Pressure ON/Spring OFF Type

27 -

- Spring ON/Pressure OFF Type

27 -

Powershift Gearbox

Clutch Operation - Forward, Reverse

30 -

Clutch Operation - Mainshaft, Layshaft, 6 Speed

30 -

Clutch Operation - 2/4 Wheel Drive

30 -

Electrical Connections

Powershift Gearbox - 4 Speed

32 -

Powershift Gearbox - 6 Speed (ShiftMaster)

33 -

Fault Finding

Synchro Shuttle Gearbox

35 -

2/4 Wheel Drive Clutch

36 -

Powershift Gearbox

40 -

Continued...

9803/3280

Issue 3*

Section F

Transmission

Section F

Contents

Page No.

Service Procedures

Front Axle - SD55, SD70

Renewing the Pinion Oil Seal

50 -

Rear Axle - SD80, PD70

Renewing the Pinion Oil Seal

51 -

Brakes - Testing for Piston Seal Leakage

52 -

Synchro Shuttle Gearbox

Stall Test

55 -

Pressure and Flow Tests

55 -

Forward/Reverse Solenoid Control Valve

Dismantling and Assembly

57 -

Powershift Gearbox

Gearbox Hydraulic Pump

Removal and Replacement

63 -

Suction Strainer

Removal and Replacement

64 -

Stall Test

65 -

Pressure and Flow Tests

66 -

Speed Sensor - Testing

67 -

ShiftMaster

Electronic Control Unit

68 -

Diagnostics User Guide

69 -

Diagnostics Troubleshooting Guide

70 -

Propshafts

Removal and Replacement

75 -

Front Axle - SD 55/SD70

Removal and Replacement

80 -

Hub and Driveshaft

Dismantling and Assembly

81 -

Drivehead - SD55

Dismantling and Assembly

82 -

Drivehead - SD70

Dismantling and Assembly

83 -

Crownwheel and Pinion Meshing

83 -

Front Axle - (2 wheel drive machines)

Removal and Replacement

85 -

Dismantling and Assembly

86 -

Continued...

9803/3280

Issue 2*

Section F

Transmission

Section F

iii

Contents

Page No.

Rear Axle - PD70, SD80

Removal and Replacement

90 - 1

Brakes

Dismantling and Assembly

91 - 1

Hub and Driveshaft - SD80

Dismantling and Assembly

92 - 1

Hub and Driveshaft - PD70

Dismantling and Assembly

93 - 1

Drivehead

Dismantling and Assembly

94 - 1

Crownwheel and Pinion Meshing

94 - 8

Axles

Collapsible Spacer

95 - 1

Limited Slip Differential

Dismantling and Assembly

100 - 1

Synchro Shuttle Gearbox

Removal and Replacement

105 - 1

Dismantling

110 - 1

Inspection

111 - 1

Assembly

112 - 1

Clutch Dismantling and Assembly Procedures

Forward/Reverse Clutch

113 - 1

2/4 Wheel Drive Clutch (4WD Pressure On)

114 - 1

2/4 Wheel Drive Clutch (4WD Pressure Spring On)

115 - 1

2/4 Wheel Drive Clutch Pressure Testing

116 - 1

Piston Ring Seals - Fitting Procedure

117 - 1

Powershift Gearbox

Removal and Replacement

120 - 1

Dismantling

125 - 1

Inspection

126 - 1

Assembly

127 - 1

Clutch Dismantling and Assembly Procedures

Forward/Input and Reverser Clutch

130 - 1

Layshaft Clutch

131 - 1

Mainshaft Clutch

132 - 2

6 Speed Clutch

133 - 1

2/4 Wheel Drive Clutch

134 - 1

Piston Ring Seals - Fitting Procedure

140 - 1

Torque Converter

Removal and Replacement

150 - 1

9803/3280

Issue 2*

Section 1

Transmission

Section 1

1 - 2

Service Tools

1 - 2

Service Tools (cont'd)

892/00179

Bearing Press (use with

appropriate adapters)

892/00812

Drive Coupling Spanner

S188200

S107750

992/07608

Bearing Adapter

992/07609

Bearing Adapter

992/07610

Bearing Adapter

992/07611

Bearing Adapter

992/07612

Bearing Adapter

992/07613

Bearing Adapter

Powershift Gearbox Flow Test Adaptor

460/15708 Flow Test Adapter

460/15707 Banjo Bolt

S188160

2401/0222 O-ring

2403/0110 O-ring

2403/0108 O-ring

1604/0004 Adapter

1406/0018 Sealing Washer

892/00922

12.2” Torque Converter Alignment Tool

S267260

892/00920 Flow Test Adapter

892/00301 Flow Test Adapter

892/00302 Flow Test Adapter

A313250

S188210

9803/3280

Issue 1

Section F

Transmission

Section F

1 - 3

Service Tools

1 - 3

892/00224

Impulse Extractor Set for Hub Bearing Seals

S261230

S197070

Torque Measuring Tool for Wheel Hub Seals

Manufacture locally, procedures in this manual show

checking the wheel hub seal using a rolling force.

However, the torque can be measured using above

locally manufactured tool.

Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft)

excluding seal drag. Maximum permissible including

seal drag is 40 Nm (29.5 lbf ft).

892/00225

Adapter - Impulse Extractor

Small

17mm to 25mm

892/00891

Medium 25mm to 45mm

Large

45mm to 80mm

Fitting Tool Assembly for

993/59500

Adapter - Impulse Extractor (syncro

Wheel Hub Seals

shuttle and powershift transmission)

S227760

S216290

892/00817

17 mm A/F x 3/4in. square drive

892/00818

22 mm A/F x 3/4in. square drive

892/00819

15 mm A/F x 1/2in. square drive

892/00333

19 mm A/F x 3/4in. square drive

9803/3280

Issue 1

Section F

Transmission

Section F

1-5

Service Tools

1-5

Hydraulic Circuit Pressure Test Kit (also used for main hydraulic

system tests)

892/00253

Pressure Test Kit

:892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in²)

:892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in²)

:892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in²)

S267300

:892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with

probe 892/00706)

892/00706

Test Probe

S188121

Flow Test Equipment (also used for main hydraulic system

tests)

892/00268

Flow Monitoring Unit

892/00269

Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00293

Connector Pipe

892/00270

Load Valve

1406/0021

Bonded Washer

1604/0006

Adapter 3/4 in M x 3/4 in M BSP

1612/0006

Adapter 3/4 in F x 3/4 in M BSP

892/00271

Adapter 3/4 in F x 5/8 in M BSP

892/00272

Adapter 5/8 in F x 3/4 in M BSP

816/20008

Adapter 3/4 in F x 1/2 in M BSP

892/00275

Adapter 1/2 in F x 3/4 in M BSP

892/00276

Adapter 3/4 in F x 3/8 in M BSP

892/00277

Adapter 3/8 in F x 3/4 in M BSP

892/00273

Sensor Head 0 - 380 l/min

892/00294

Connector Pipe

1606/0015

Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078

Connector 1 in F x 1 in F BSP

1604/0008

Adapter 1 in M x 1 in M BSP

S188151

1606/0012

Adapter 1 in M x 3/4 in M BSP

816/20013

Adapter 3/4 in F x 1 in M BSP

S316250

Test Point

892/00964

Test point (1/8 BSP) Powershift

892/00965

Test point (3/8 BSP) Powershift

892/00966

Test point (1/4 BSP) Synchro Shuttle

These test points can be left in position after testing.

9803/3280

Issue 1

Section F

Transmission

Section F

1 - 7

Service Tools

1 - 7

Service Tools (cont'd)

Solid Spacer Setting Kit

921/53400

Spacer Kit - Sychro Shuttle Gearbox,

Synchro Shuttle Gearbox, SD70, SD80

SD70, SD80 Axles

Axles

Comprises of:

892/00918

Setting Tool Kit

Spacer thickness mm

921/52627

Spacer 14.20 Service use

921/52628

12.600

993/70111

Breakback Torque Wrench

829/30405

12.625

892/01076

Support Bracket -

921/52629

12.650

Synchro Shuttle Gearbox

829/30406

12.675

921/52630

12.700

892/01075

Support Bracket

829/30407

12.725

PD70, SD80 Rear Axles

921/52601

12.750

997/11000

Support Bracket

829/30408

12.775

SD55, SD70 Front Axles

921/52602

12.800

998/10567

SD80 Pinion Shaft Adaptor

829/30409

12.825

921/52603

12.850

921/53300

Spacer Kit - SD55 Axles

829/30410

12.875

921/52604

12.900

Comprises of:

829/30411

12.925

Spacer thickness mm

921/52605

12.950

921/53322

13.550

829/30412

12.975

921/53323

13.575

921/52606

13.000

829/30413

13.025

921/53324

13.600

921/52607

13.050

921/53325

13.625

829/30414

13.075

921/53301

13.650

921/52608

13.100

921/53302

13.675

829/30415

13.125

921/53303

13.700

921/52609

13.150

921/53304

13.725

829/30416

13.175

921/53305

13.750

921/52610

13.200

921/53306

13.775

829/30417

13.225

921/53307

13.800

921/52611

13.250

921/53308

13.825

921/53424

13.275

921/53309

13.850

921/53425

13.300

921/53310

13.875

921/53426

13.325

921/53311

13.900

921/53427

13.350

921/53428

13.375

921/53312

13.925

921/53401

13.400

921/53313

13.950

921/53402

13.425

921/53314

13.975

921/53403

13.450

921/53315

14.000

921/53404

13.475

921/53316

14.025

921/53405

13.500

921/53317

14.050

921/53406

13.525

921/53318

14.075

921/53407

13.550

921/53319

14.100

921/53408

13.575

921/53320

14.125

921/53409

13.600

921/53321

14.150

921/53410

13.625

921/53411

13.650

921/53412

13.675

921/53413

13.700

921/53414

13.725

921/53415

13.750

921/53416

13.775

921/53417

13.800

921/53418

13.825

921/53419

13.850

921/53420

13.875

921/53421

13.900

921/53422

13.925

921/53423

13.950

921/52626

14.000

Note: After using a spacer, obtain a replacement to keep

the set complete

9803/3280

Issue 1

Section F

Transmission

Section F

1 - 8

Service Tools

1 - 8

Service Tools (cont'd)

892/01083

Powershift - Assembly tool,

transfer gear

892/01084

Powershift - Transfer gear, bearing

assembly

892/01085

Powershift - Seal fitting tool

892/01094 Transmission Jack

When removing the Powershift gearbox use of a special

transmission jack is strongly recommended. This jack

can also be used when removing Synchro Shuttle

gearboxes.

Note that the jack must be used with special support

plates, see the facing page for details.

A402680

823/10420

Thrust Washer Kit - Powershift

gearbox - Layshaft clutch

Comprises of:

Washer thickness mm

823/10421

4.3

823/10422

4.4

823/10423

4.5

823/10424

4.6

823/10425

4.7

823/10426

4.8

892/01096

Speed Sensor Test Harness -

Powershift Gearbox

9803/3280

Issue 3*

Section F

Transmission

Section F

1 - 11

Service Tools

1 - 11

Service Tools (cont'd)

Powershift Gearbox - hydraulic pump removal tools

The tools detailed below enable the pump to be removed

with the torque converter housing in place.

Reaction bar. Locally manufacture from mild steel bar.

Drill the 2 holes through the bar as shown.

2 off lengths of M10 x 1.5 threaded rod 250 mm (10 in)

long.

2 off M10 x 1.5 nuts.

A set of M10 x 1.5 taps will also be required.

12 mm

500 mm

121.5 mm

32 mm

11.0 mm

A406000

Powershift Gearbox - 6 Speed (ShiftMaster)

Electronic Service Tool Kit

892/01033 Kit comprises:

Data Link Adaptor (DLA), enables data exchange

between the machine ECU (Electronic Control Unit) and

a laptop PC loaded with the applicable ShiftMaster

diagnostics software.

Interconnecting cable, DLA to laptop PC. Several cables

are included to enable compatibility with different PC

port types.

Interconnecting cable, DLA to machine ECU diagnostics

socket.

Kit carrying case.

A406130

9803/3280

Issue 1

Section F

Transmission

Section F

2 - 1

Technical Data

2 - 1

Tyre Pressures

Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

Front Wheels

AWS/4WD MACHINES

Item Size x Ply

Type

Make

Remarks

Pressure

bar

lbf/in²

16.9x24x12

IND

ARMSTRONG

TUBELESS

2.6

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

15.5x25

XTLA

MICHELIN

TUBELESS

2.5

16.9x28x12

IND

ARMSTRONG

TUBELESS

2.6

16.9x28x12

IND

GOODYEAR

TUBELESS

2.6

16.9x28x10

IND

GOODYEAR

TUBELESS

2.2

16.9x28

XM27

MICHELIN

TUBELESS

2.7

16.9x28x14

IND

NOKIA

TUBE

2.6

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

16.9x28x12

TRAC

OLYMPIC

TUBELESS

2.6

16.9x28x12

IND

OLYMPIC

TUBE

2.6

14.9x24x12

IND

GOODYEAR

TUBELESS

2.75

16.9x28

IND

GOODYEAR

TUBELESS

2.5

2WS/2WD MACHINES

11.0x16x12

RIB

ARMSTRONG

TUBELESS

4.4

11.0x16x12

RIB

GOODYEAR

TUBELESS

4.2

11Lx16x12

IND

ARMSTRONG

TUBELESS

4.4

10.5x18x10

IND

FIRESTONE

TUBELESS

3.8

12.0x18x12

IND

FIRESTONE

TUBELESS

3.5

2WS/4WD MACHINES

14x17.5x10

IND

ARMSTRONG

TUBELESS

3.8

14x17.5x10

IND

GOODYEAR

TUBELESS

3.8

12.0x18x12

IND

FIRESTONE

TUBELESS

3.5

12.0x18x12

IND

OLYMPIC

TUBELESS

4.25

335 x18

XM27

MICHELIN

TUBELESS

3.5

12.5x18x10

IND

GOODYEAR

TUBELESS

4.25

335 x20

XM27

MICHELIN

TUBE

3.0

43.5

340 x18

IND

GOODYEAR

TUBELESS

3.2

Items 4, 5, 6, 7,8, 9, 10, 11, 13, 38 must have steering lock restriction stops fitted.

9803/3280

Issue 1

Section F

Transmission

Section F

2 - 2

Technical Data

2 - 2

Tyre Pressures

Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

Rear Wheels

AWS MACHINES

Item Size x Ply

Type

Make

Remarks

Pressure

bar

lbf/in²

16.9x24x12

IND

ARMSTRONG

TUBELESS

2.6

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

15.5x25

XTLA

MICHELIN

TUBELESS

2.5

16.9x28x12

IND

ARMSTRONG

TUBELESS

2.6

16.9x28x12

IND

GOODYEAR

TUBELESS

2.6

16.9x28x10

IND

GOODYEAR

TUBELESS

2.2

16.9x28

XM27

MICHELIN

TUBELESS

2.7

16.9x28x14

IND

NOKIA

TUBE

2.6

16.9x24x12

IND

GOODYEAR

TUBELESS

2.6

16.9x28x12

TRAC

OLYMPIC

TUBELESS

2.6

16.9x28x12

IND

OLYMPIC

TUBE

2.6

14.9x24x12

IND

GOODYEAR

TUBELESS

2.75

16.9x28

IND

GOODYEAR

TUBELESS

2.5

2WS MACHINES

16.9x24x10

IND

ARMSTR0NG

TUBELESS

2.2

16.9x24x12

IND

GOOOYEAR

TUBELESS

2.2

19.5x24x10

IND

ARMSTRONG

TUBELESS

1.9

19.5x24x12

IND

ARMSTRONG

TUBELESS

2.3

21L x24x12

IND

GOODYEAR

TUBELESS

2.2

18.4x26x12

TRAC

GOODYEAR

TUBELESS

2.5

18.4x26x12

TRAC

OLYMPIC

TUBELESS

2.4

18.4x26x12

IND

GOODYEAR

TUBELESS

2.0

16.9x28x12

TRAC

OLYMPIC

TUBELESS

2.2

16.9x28x12

TRAC

FIRESTONE

TUBE

2.2

16.9x28x12

IND

GOODYEAR

TUBELESS

2.2

16.9x28

XM27

MICHELIN

TUBELESS

2.5

18.4x30x14

IND

GOODYEAR

TUBE

2.0

16.9x28

IND

GOODYEAR

TUBELESS

2.5

Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table

above.

Items 4, 5, 6, 7,8, 9, 10, 11, 13 must have steering lock restriction stops fitted.

9803/3280

Issue 1

Section F

Transmission

Section F

3 - 1

Technical Data

3 - 1

Front Axle

Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle

with a different ratio to the axle being replaced.

ALL WHEEL STEER MACHINES

Type

JCB spiral bevel input with epicyclic hub reduction

Designation

SD70

Installation

Centre pivot

Weight

(dry, with no steer rams and without wheels)

385 kg (850 lbs) approximately

Overall Gear Ratio

24.975:1

Crownwheel and Pinion Ratio

4.625:1

Number of Teeth

Crownwheel

Pinion

Hub Reduction

5.4:1

Input Type

Yoke

Oscillation

± 5°

Toe - in

0°

Castor Angle

0°

Camber Angle

1°

King - pin inclination

0°

2 WHEEL STEER MACHINES (4 Wheel Drive)

Type

JCB spiral bevel input with epicyclic hub reduction

Designation

SD55

Installation

Centre pivot

Weight

(dry, with no steer rams and without wheels)

330 kg (728 lbs) approximately

Hub Reduction

5.4:1

Input Type

Yoke

Oscillation

± 5°

Toe - in

0 °

Castor Angle

0 °

Camber Angle

1 °

King - pin inclination

0 °

Ratios

OPTION 1

OPTION 2

Overall

16.2:1

19.2:1

Crownwheel and Pinion

3:1

3.556:1

Number of Teeth

Crownwheel

Pinion

2 WHEEL STEER MACHINES (2 Wheel Drive)

Type

JCB centre oscillation, non-driven

Installation

Centre pivot

Weight

(dry, with steer ram and without wheels)

239 kg (525 lbs) approximately

Oscillation

± 5°

Toe - in

0°

Castor Angle

0°

Camber Angle

3 ° positive

9803/3280

Issue 1

Section F

Transmission

Section F

3 - 2

Technical Data

3 - 2

Rear Axle

Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle

with a different ratio to the axle being replaced.

ALL WHEEL STEER MACHINES

Type

3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard

braking. Pinion mounted park brake disc.

Designation

SD80

Installation

Rigid pad mount

Number of steer rams

1 (Double rod)

Weight (dry, with no steer rams

410 kg (904 lbs) approx.

and without wheels)

Half (Axle) Shaft Braking/Type

5 friction plate, 6 counter plate (each half shaft)

Input Type

Yoke

Oscillation

± 5°

Toe - in

0 °

Castor Angle

0 °

Camber Angle

1 °

King - pin inclination

0 °

Hub Reduction

5.4:1

Ratios

OPTION 1

OPTION 2

OPTION 3

Overall

15.78:1

18.16:1

13.7:1

Crownwheel and Pinion

2.923:1

3.363:1

2.538:1

Number of Teeth

Crownwheel

Pinion

2 WHEEL STEER MACHINES

Type

3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard

braking. Pinion mounted park brake disc.

Designation

PD70

Installation

Rigid pad mount

Weight (dry and without wheels)

386 kg (851 lbs) approx.

Half (Axle) Shaft Braking/Type

5 friction plate, 6 counter plate (each half shaft)

Input Type

Yoke

Hub Reduction

5.4:1

Ratios

OPTION 1

OPTION 2

OPTION 3

Overall

15.78:1

18.16:1

13.7:1

Crownwheel and Pinion

2.923:1

3.363:1

2.538:1

Number of Teeth

Crownwheel

Pinion

9803/3280

Issue 1

Section F

Transmission

Section F

4-1

Technical Data

4-1

Synchro Shuttle Gearbox

Description

Combined torque converter, reverser, and gearbox unit.

Synchromesh manual gear selection. Electro hydraulic

selection of forward and reverse.

Designation

SS700 (4 wheel drive)

Weight (dry)

2WD

* 170 kg (375 lb)

4WD

* 200 kg (441 lb)

Gear Ratios

Std Ratio

Low Ratio

1st

5.56:1

6.56:1

2nd

3.45:1

4.06:1

3rd

1.83:1

1.90:1

4th

1.00:1

Torque Converter

Torque Converter Dia.

310 mm (12.2 in.)

Torque Converter Identification

04/600580

04/600581

Torque Multiplication at Stall

2.52:1

3.01:1

Converter Pressures (in neutral)

bar

kgf/cm²

lbf/in²

Converter In at 50 deg.C

1000 rev/min

1.5 - 2.5

22 - 36

2000 rev/min

5.3 - 6.7

5.4 - 6.8

77 - 97

Converter In at 100 deg.C

1000 rev/min

0.5 - 1.3

7 - 19

2000 rev/min

4.1 - 4.9

4.2 - 5.0

59 - 71

Converter Out at 50 deg.C

1000 rev/min

0.8 - 1.6

12 - 23

2000 rev/min

3.0 - 4.0

3.1 - 4.1

43 - 58

Converter Out at 100 deg.C

1000 rev/min

0.3 - 0.9

0.3 - 0.6

4-9

2000 rev/min

2.1 - 2.9

2.1 - 3.0

30 - 42

Lubrication Pressures (in neutral)

bar

kgf/cm²

lbf/in²

At 50 deg.C

1000 rev/min

0.3 - 0.9

4 - 13

2000 rev/min

1.8 - 2.4

26 - 35

At 100 deg.C

1000 rev/min

0.1 - 0.3

1-4

2000 rev/min

1.3 - 2.1

19 - 30

Main Line Pressure (in neutral) †

bar

kgf/cm²

lbf/in²

At 50 deg. C

1000 rev/min

11.0 - 13.0

11.2 - 13.3

159 - 188

2000 rev/min

13.0 - 15.6

13.3 - 16.0

188 - 226

At 100 deg.C

1000 rev/min

10.2 - 12.2

10.4 - 12.4

148 - 177

2000 rev/min

11.4 - 14.0

11.8 - 14.3

165 - 203

Clutch Pressures †

All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10

lbf/in²)

Flow Rates (in neutral)

L/min

US gal/min

UK gal/min

Cooler at 50 deg.C

1000 rev/min

7.7 - 11.0

2.0 - 2.9

1.7 - 2.4

2000 rev/min

13.9 - 20.0

3.6 - 5.3

3.0 - 4.4

Cooler at 100 deg.C

1000 rev/min

5.2 - 8.2

1.1 - 2.2

1.1 - 1.8

2000 rev/min

14.5 - 17.5

3.8 - 4.6

3.2 - 3.8

Pump at 50 deg.C

1000 rev/min

11.5 - 15.5

3.0 - 4.1

2.5 - 3.4

2000 rev/min

24.0 - 33.0

6.7 - 8.8

5.3 - 7.3

9803/3280

Issue 3*

JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 21