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JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 25

Section F

Transmission

Section F

50 - 1

Service Procedures

50 - 1

Front Axle - SD55, SD70

Renewing the Pinion Oil Seal

The pinion oil seal 3 may be renewed without removing the

4

Check the sealing surface on the yoke for wear or

axle from the machine.

damage. renew the yoke if necessary.

! WARNING

5

Fit the yoke and temporarily fit the old stake nut 2.

Tighten the nut with a torque wrench, aligning the

A raised and badly supported machine can fall on you.

scriber marks. Note the tightening torque required.

Position the machine on a firm, level surface before

raising one end. Ensure the other end is securely

6

Remove and discard the old nut. Fit a new nut and

chocked. Do not rely solely on the machine hydraulics or

tighten to the torque determined at step 5.

jacks to support the machine when working under it.

6.1 Measure the rolling torque. The reading should be

Disconnect the battery, to prevent the engine being

0.5 to1Nm (0.37 to 0.74lbf ft; 0.05 to 0.1kgf m)

started while you are beneath the machine.

GEN-001

more than that recorded in Step 1 (see Note).

1

Remove the roadwheels and uncouple the axle

6.2 If necessary, progressively torque tighten the nut to

propshaft. Measure the axle rolling torque and record

a maximum of 300 Nm (221 lbf ft) to achieve

the reading. Mark the relative positions of the pinion

correct rolling torque.

shaft 4 and nut 2 with a scriber.

Note: If the rolling torque figure (new pinion seal fitted)

2

Using Service Tool 892/00812, remove the drive yoke 1

exceeds the reading recorded in step 1 by 1Nm (0.74 lbf ft;

together with its stake nut 2.

0.1 kgf m) or more, or a minimum torque of 250 Nm (184 lbf

ft) can not be achieved then the pinion assembly must be re-

3

Remove the seal 3 and fit a new one. Be sure not to

built using a solid spacer, see the apprpriate axle assembly

damage the seal housing. Pack between the lips of the

procedure.

new seal with grease before fitting.

6.3 Stake the nut using a square ended staking tool.

7

Refit the roadwheels and couple the propshaft.

Typical Axle Shown

9803/3280

Issue 1

Section F

Transmission

Section F

55 - 1

Service Procedures

55 - 1

G

K

J

H

E

D

F

A396910

S266880

L

C

A

B

9803/3280

Issue 1

Section F

Transmission

Section F

57 - 1

Service Procedures

57 - 1

Synchro Shuttle Gearbox

Forward/Reverse Solenoid Control Valve

Dismantling

Unscrew the knurled nut 2 and remove 'O' ring 3, withdraw

the solenoid 4 and 'O' ring 5.

Hold the solenoid valve body 6 in a vice, using the spanner

flats A, remove spindle 7 and 'O' ring 8.

Pull out actuating pin 9, spring 10, spring retainer 11, and

spool 12.

Inspect the spool and spool bore for signs of wear, nicks

scratches etc.

Assembling

Assembly is reversal of the dismantle procedure.

Renew all 'O' rings.

Lightly lubricate all parts with clean transmission fluid before

assembling.

Check that the flying leads are secure and that the

connectors are intact.

Torque Settings

Item

Nm

kgf m

lbf ft

2

10 to 15

1 to 1.5

8 to 10

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Issue 1

Section F

Transmission

Section F

63 - 1

Service Procedures

63 - 1

2

6

B

B

1

A

D

C

D

2

C

3

X

5

4

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Issue 1

Section F

Transmission

Section F

64 - 1

Service Procedures

64 - 1

Powershift Gearbox

Suction Strainer - Removal and Replacement

Removal

Replacement

The suction strainer is located inside the gearbox front case.

Replacement is the reverse of the removal sequence but

Access is gained by removing the 4WD clutch assembly.

note the following:

1

Park the machine on level ground, apply the parking

1

Fit a new gasket C.

brake and chock the wheels.

2

Make sure that no loose components or debris have

2

Allow transmission oil to cool and then drain the oil, see

been left inside the gearbox casing.

Powershift Gearbox, Changing the Oil, Routine

Maintenance.

3

Before replacing the 4WD assembly make sure that all

traces of gasket or gasket compound have been

3

Disconnect the propshaft from the 4WD unit, see

removed from the mating faces, see Powershift,

Propshaft, Removal and Replacement.

Gearbox, Inspection.

4

Remove the 4WD unit, see Powershift Gearbox,

Dismantling Step 6 - Remove the 4WD Clutch

Assembly.

5

Using a 13 mm ring spanner, reach inside the casing

and undo the 2 suction strainer retaining bolts A. Be

sure to retrieve the bolts from inside the gearbox.

6

Push the suction strainer B away from you (towards the

rear of the gearbox) to disengage it from the gearbox

casing. Remove the strainer via the 4WD aperture.

7

Make sure that the gasket C is retrieved. Discard the

gasket.

8

Clean the suction strainer by flushing with a solvent

cleaner. Inspect the strainer mesh for tears or splits.

Renew the suction strainer if the mesh is damaged.

A

C

B

A

A403940

9803/3280

Issue 1

Section F

Transmission

Section F

65 - 1

Service Procedures

65 - 1

Powershift Gearbox

Torque Converter Stall Test

The purpose of the stall test is to check the performance of

Note: When fully engaged, the parking brake electrically

the transmission by ‘stalling’ the torque converter. This is the

disconnects the transmission drive; this prevents the

point at which, due to torque applied by the engine the

machine from being driven with the parkbrake on. Therefore,

torque converter stops transmitting drive to the gearbox.

so that we can complete the test, move the parkbrake lever

The engine speed at which ‘stalling’ occurs is compared to

fractionally forward until the warning light is just

speeds recorded for a machine in normal condition (given in

extinguished; hold the lever in this position for the duration

Technical Data). Abnormal stall speed results can be used

of the test. DO NOT move the lever too far forward,

to identify a number of possible faults with the transmission,

otherwise the parkbrake will not be fully operational.

typically gearbox hydraulic and clutch faults.

Alternatively, disconnect the switch at the park brake.

Note: DO NOT stall the converter for longer than 10 seconds

3

Select 1st speed forward drive and open throttle fully.

or the transmission fluid will overheat. Make sure that the oil

Record the engine speed from the tachometer. Repeat

level is correct and at normal operating temperature.

the test for 2nd and 3rd speed forward and record the

readings.

Before completing the following test, remove the

transmission dipstick. If there is any sign of smoke emitting

4

Repeat step 3 except this time select 1st, 2nd and 3rd

from the dipstick tube STOP THE TEST IMMEDIATELY and

gear reverse drive respectively. Record the readings.

dismantle the transmission for servicing.

5

All recorded readings should be as specified at Torque

By performing the tests in the first 3 gears in forward and

Converter Stall in Transmission Technical Data.

reverse we can see from the tables below that all the

clutches in the gearbox will be engaged, ensuring faults will

Key to Clutches

be easy to identify. Draw a table as shown so that you can

T - Forward low ratio clutch pressure

record the results.

U - Forward high ratio clutch pressure

Stall Test Results - 6 Speed Powershift

V - Reverse high ratio clutch pressure

Gear

Clutches engaged

W- Reverse low ratio clutch pressure

Forward

Rev/min

Reverse

Rev/min

X - 6 speed clutch pressure (6 speed gearbox only)

Y - Mainshaft clutch pressure

1st

X,Z

W,Z

Z - Layshaft clutch pressure

2nd

T,Z

V,Z

3rd

U,Z

W,Y

Stall Test Results - 4 Speed Powershift

Gear

Clutches engaged

Forward

Rev/min

Reverse

Rev/min

1st

T,Z

W,Z

2nd

U,Z

V,Z

3rd

T,Y

W,Y

1

Ensure that the engine and transmission are at normal

working temperature (the transmission oil must be

above 50°C). Run engine at maximum speed and check

the No Load Speed (High Idle Speed - U.S.A). See

Engine Technical Data for correct figure; adjust if

necessary.

2

Apply parking brake and footbrake firmly. If necessary,

set the machine against a fixed obstruction.

9803/3280

Issue 1

Section F

Transmission

Section F

65 - 2

Service Procedures

65 - 2

Powershift Gearbox

Torque Converter Stall Test, cont’d

Interpreting the Test Results

If all the engine speeds are below the stated figures either

the engine is losing power and should be

serviced/overhauled or the torque converter reaction

member clutch is slipping. To check the engine, select

Neutral, open throttle fully and operate an excavator service

to 'blow off' the main relief valve. Engine speed should fall to

slightly below the Maximum Governed Speed (see Engine

Technical Data). If engine speed is correct the torque

converter reaction member clutch is slipping.

If all the engine speeds are higher than the stated figures in

all gears the torque converter safety relief valve may be

faulty. Alternatively there may be internal oil leakage.

If engine speeds are higher than the stated figures in some

gears, check the transmission for clutch slippage or internal

leakage. Look at the example below and see how the results

can be used to isolate a suspect clutch.

Stall Test Results - 6 Speed Powershift

Gear

Clutches engaged

Forward

Rev/min

Reverse

Rev/min

1st

X,Z

1990

W,Z

1980

2nd

T,Z

2060

V,Z

1975

3rd

U,Z

1985

W,Y

1990

In the example shown, we can see that the engine speed is

abnormally high when 2nd gear forward drive is selected,

indicating a slipping clutch, possibly T or Z. We can now use

the results to determine which clutch is at fault.

From the table we can see that there is no problem with

clutch Z since it is engaged in other gears, the stall speeds

for those gears are normal. This indicates that clutch T is

slipping.

Clutches may be slip for several reasons. Hydraulic leakage

is possible and this can be confirmed by carring out a

pressure test, see Pressure Testing - Individual Clutches.

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 1

Service Procedures

66 - 1

Powershift Gearbox

Pressure and Flow Testing

J

Y

Z

A

T

U

S

L

X

M

F

B

C

W

V

A396470

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 3

Service Procedures

66 - 3

Powershift Gearbox

Pressure and Flow Testing

A

B

A396990

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 4

Service Procedures

66 - 4

Powershift Gearbox

Pressure and Flow Testing, cont’d

Pump Flow

Mainline Pressure

1

Stop engine, remove the gearbox oil filter and fit

1

Stop engine, connect a 0-20 bar (0-300 lbf/in²) pressure

adapter X

(460/15708) into the gearbox casing.

gauge to test connector A.

Connect flowmeter W (892/00268).

2

Start engine and run at

1000 rev/min. With the

2

Start engine and run at

1000 rev/min. With the

transmission in neutral the pressure gauge will show

transmission in neutral the flowmeter will show the

the Main Line Pressure which should be as shown in

Pump Flow which should be as shown in Technical

Technical Data. A low reading can be caused by either

Data. A low reading indicates a worn pump or blocked

a faulty pressure maintenance valve or a worn pump. A

suction strainer.

high or low reading may indicate a faulty pressure

maintenance valve.

3

Repeat step 2 and note gauge readings with engine

running at 2000 rev/min.

3

Repeat step 2, with engine running at 2000 rev/min

note gauge readings which should be as shown in

4

Stop engine and remove test adapters, refit filter.

Technical Data.

4

Stop engine and remove test gauge.

Converter In Pressure

Note that the converter in pressure is affected by the torque

converter relief valve operation. Before carrying out tests

check the operation of the relief valve (see Converter Relief

(Safety) Valve Pressure).

1

Stop engine, connect a 0-20 bar (0-300 lbf/in²) pressure

gauge to test point B.

2

Start the engine and run at 1000 rev/min. With the

transmission in neutral the pressure gauge will show

Converter In Pressure which should be as shown in

Technical Data. A high or low reading could indicate a

faulty converter relief valve.

3

Remove pressure test gauge.

W

X

A396980

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 5

Service Procedures

66 - 5

Powershift Gearbox

Pressure and Flow Testing

J

C

K

B

P

A397000

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 7

Service Procedures

66 - 7

Powershift Gearbox

Pressure and Flow Testing

J

Y

Z

A

T

U

S

L

X

M

F

B

C

W

V

A396470

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 8

Service Procedures

66 - 8

Powershift Gearbox

Pressure Testing - Clutches

Isolating a Suspect Clutch

By performing the tests in the first 3 gears in forward and

3

Start engine and run at 1000 rev/min, engage 1st gear

reverse all the clutches in the gearbox will be engaged,

forward. Record the pressure reading. Repeat the test

ensuring any clutch leakage will be easy to identify. Draw a

for 2nd and 3rd gears forward and 1st, 2nd and 3rd

table as shown so that you can record the results.

gears revers. Record the pressure readings as shown in

the example below:

Clutch Pressure Test Results - 6 Speed Powershift

Clutch Pressure Test Results - 6 Speed Powershift

Gear

Clutches engaged

Gear

Clutches engaged

Forward

bar

lbf/in2

Reverse

bar

lbf/in2

Forward

bar

lbf/in2

Reverse

bar

lbf/in2

1st

X,Z

W,Z

1st

X,Z

13.4

194

W,Z

13.4

194

2nd

T,Z

V,Z

2nd

T,Z

12.0

175

V,Z

13.6

197

3rd

U,Z

W,Y

3rd

U,Z

13.5

195

W,Y

13.5

195

Readings should not vary between clutches by more than

Clutch Pressure Test Results - 4 Speed Powershift

0.7 bar (10 lbf/in²). In the example shown, we can see that

Gear

Clutches engaged

pressure is low when 2nd gear forward is selected,

Forward

bar

lbf/in2

Reverse

bar

lbf/in2

indicating clutch leakage.

1st

T,Z

W,Z

From the table we that the layshaft clutch Z is working

normally (1st and 3rd gear forward and 1st and 2nd gears

2nd

U,Z

V,Z

reverse all show normal operating pressure). We can

assume that the forward low clutch T is leaking.

3rd

T,Y

W,Y

By carring out ‘Individual Clutch Leakage Tests', (see next

page) we can confirm that the forward low clutch T is

1

Stop engine, connect a 0-20 bar (0-300 lbf/in²) pressure

leaking.

gauge to test connector A (mainline pressure test

point).

2

Make sure that both sides of all four wheels are

chocked. Apply the footbrake and parking brake.

Note: When fully engaged, the parking brake electrically

disconnects the transmission drive; this prevents the

machine from being driven with the parkbrake on. Therefore,

so that we can complete the test, move the parkbrake lever

fractionally forward until the warning light is just

extinguished; hold the lever in this position for the duration

of the test. DO NOT move the lever too far forward,

otherwise the parkbrake will not be fully operational.

Alternatively, disconnect the switch at the park brake.

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 9

Service Procedures

66 - 9

Powershift Gearbox

Pressure and Flow Testing

J

Y

Z

A

T

U

R

S

L

X

M

F

B

C

W

V

A396470

9803/3280

Issue 1

Section F

Transmission

Section F

66 - 10

Service Procedures

66 - 10

Powershift Gearbox

Pressure Testing - Clutches

Individual Clutch Leakage Test

When testing individual clutch pressures it is necessary to

In the following procedures the forward low clutch (T) is

isolate the clutch being tested. So for instance, on a 6 speed

tested, therefore in step 2 a pressure gauge is connected to

gearbox, to check the forward low clutch T we must select

the forward low clutch test point.

2nd gear forward - this would energise the forward low (T)

and layshaft (Z) clutches. Because we only want to check

When testing other suspect clutches connect a gauge to the

the forward low (T) clutch pressure and not the layshaft (Z)

relevant suspect clutch test point. Because the forward low

clutch pressure, remove the electrical connector to the 6

clutch is suspect, a gear must be selected that will use the

speed clutch solenoid Zs BEFORE selecting 2nd gear.

forward low clutch, in this instance 2nd gear forward.

Use the table below to determine which solenoid electrical

Note: When testing the 2/4WD clutch remove the feed pipe

connectors should be removed when pressure testing

R and fit service tool. This pipe incorporates a test point.

individual clutches. Note that as the first 3 forward and

Replace the original pipe when testing is complete.

reverse gears utilise all clutches, there is no need to select

other gears when testing for leakage.

1

Stop engine, connect a 0-20 bar (0-300 lbf/in²) pressure

gauge to test connector A, (mainline pressure test

6 Speed Gearbox

point).

Gear

Clutches Engaged (Solenoids Energised)

Selected

2

Connect a 0-20 bar (0-300 lbf/in²) pressure gauge to

test connector T (forward low ratio clutch test point).

1st Forward

6 Speed & Layshaft - X,Z

(Xs,Zs)

2nd Forward

Forward Low & Layshaft - T,Z

(Ts,Zs)

3

Remove the layshaft clutch solenoid feed connector Zs,

3rd Forward

Forward High & Layshaft - U,Z

(Us,sZ)

at the solenoid control valve. This ensures that only the

forward low clutch T is energised when 2nd gear

1st Reverse

Reverse Low & Layshaft - W,Z

(Ws,Zs)

forward is selected.

2nd Reverse

Reverse High & Layshaft - V,Z

(Vs,Zs)

3rd Reverse

Reverse Low & Mainshaft - W,Y (Ws,Ys)

4

Make sure that both sides of all four wheels are

chocked. Apply the footbrake and parking brake.

4 Speed Gearbox

Note: When fully engaged, the parking brake electrically

Gear

Clutches Engaged (Solenoids Energised)

disconnects the transmission drive; this prevents the

Selected

machine from being driven with the parkbrake on. Therefore,

so that we can complete the test, move the parkbrake lever

1st Forward

Forward Low & Layshaft - T,Z

(Ts,Zs )

fractionally forward until the warning light is just

2nd Forward

Forward High & Layshaft - U,Z

(Us,Zs)

extinguished; hold the lever in this position for the duration

3rd Forward

Forward Low & Mainshaf - T,Y

(Ts,Ys)

of the test. DO NOT move the lever too far forward,

otherwise the parkbrake will not be fully operational.

1st Reverse

Reverse Low & Layshaft - W,Z (Ws,Zs)

Alternatively, disconnect the switch at the park brake.

2nd Reverse

Reverse High & Layshaft - V,Z

(Vs,Zs)

3rd Reverse

Reverse Low & Mainshaft - W,Y (Ws,Ys)

5

Start engine and run at 1000 rev/min, select 2nd gear

forward. Note the pressure readings on both gauges,

which should not vary by more than 0.7 bar (10 lbf/in²).

If the difference on the gauges is greater than 0.7 bar

(10 lbf/in²) do the following:

Ts

Us

Ws

Vs

a Stop the engine and interchange the gauges.

b Start the engine and run at 1000 rev/min, select

2nd gear forward. If the difference on the gauges is

still greater than 0.7 bar (10 lbf/in²) dismantle the

forward low clutch for servicing.

c If after interchanging the gauges, the readings are

different than at step 5, have the gauges calibrated

and repeat the testing procedure.

Ss

Ys

Zs

Xs

9803/3280

Issue 1

Section F

Transmission

Section F

67 - 1

Service Procedures

67 - 1

Powershift Gearbox

Speed Sensor

Powershift machines fitted with an electronic control unit

(ShiftMaster ECU) or a speedometer have a speed sensor D

fitted. The speed sensor detects the speed of rotation of the

gearbox output shaft and relays this information to the ECU

or speedometer as applicable.

The sensor detects the passing of the gear teeth on the

output gear. When adjacent to the top of a gear tooth the

sensor electrical output turns ON, when adjacent to a gap

between the teeth the sensor output turns OFF. In this way

the frequency of the electrical signal changes according to

D

the speed of gear rotation and therefore machine road

speed.

The ShiftMaster ECU uses the input from the speed sensor

to determine gear shift points. Failure of the speed sensor

or its wiring will enable an ECU ‘Limp Mode’, preventing the

use of 4th, 5th, and 6th gears. See Fault Finding -

Powershift Gearbox.

Testing

The speed sensor can be tested in situ without removing it

by means of service test harness 892/01096 .

E

1

Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.

Lower the loader arms to the ground. Switch OFF the

engine and remove the starter key.

2

Connect the test harness E as shown. Tie back and

secure the wires clear of the driveshaft and other

moving components, in a position where the light

emitting diode (LED) can be seen while operating the

machine.

3

Turn the engine ON and drive the machine forward

B

A

approximately 2 m (6 ft), make sure it is clear in front.

Alternatively raise the wheels off the ground. If the

C

sensor is operating correctly the LED will illuminate as

the gear teeth pass the sensor, when the speed

Key:

increases the LED will flash at a greater frequency until

becoming continuously illuminated at higher speeds.

A Ground

B +V

4

If the LED fails to illuminate carefully check the relevant

C Output

wires and connectors for damage. Repair as required

and re-test the sensor as described above. It should be

noted that the speed sensor is normally a reliable

component and a fault is more likely attributed to

A405380

damaged wires or electrical connectors, see Electrical

Connections - Powershift Gearbox - 6 Speed.

9803/3280

Issue 1

Section F

Transmission

Section F

68 - 1

Service Procedures

68 - 1

Powershift Gearbox - 6 Speed (ShiftMaster)

Electronic Control Unit

The PS766 6 speed gearbox is controlled by an Electronic

Software Upgrades

Control Unit (ShiftMaster ECU). The ECU is located behind

From time to time a ShiftMaster ECU ‘Application Software’

the front console as shown at A.

upgrades may be made available by JCB Service. If

necessary ‘Application Software’ can be loaded into the

The ECU is housed in a rugged case protected from ingress

ECU flash memory using a laptop PC and the ShiftMaster

of dirt and moisture. Gearbox faults are more likely to be

Flash Programmer application. This application is part of

caused by faulty or damaged wiring, electrical components

the JCB Service Master package found on the JCB Service

or hydraulic faults than by failure of the ShiftMaster ECU.

Technical Information CD’s. The Flash Programmer

application includes comprehensive help files.

Fault Finding

Note that the ECU contains 2 sets of software, ‘Application

When fault finding note the following:

Software’ and ‘Setup Data’. The ‘Setup Data’ is specific to a

machine variant and can not be changed or replaced.

Make sure you understand the normal operation

characteristics of the 6 speed gearbox. Some characteristics

Renewing The ECU

may be interpreted as faults by some operators. See Basic

Before renewing the ECU note the following:

Operation - ShiftMaster Operation Characteristics.

The ShiftMaster ECU is a non serviceable part. Any units

The ShiftMaster ECU incorporates ‘Limp Modes’. These

returned under warranty found to have been tampered with

modes can operate in response to other gearbox faults.

will invalidate any claim.

Make sure you understand the characteristics of the ‘Limp

Modes’, see Fault Finding - Powershift Gearbox.

ECU’s are configured at the factory for each machine variant

and are not interchangeable between machines. Although

The simplest and best way to fault find the 6 speed gearbox

the part numbers may be the same, the internal software

electrical system, (including the ECU) is by using ShiftMaster

may not be. DO NOT interchange ECU’s between

Diagnostics software and a laptop PC. See Diagnostics

machines.

User Guide. This diagnostics system enables the engineer

to quickly identify faults with specific electrical circuits or

Before renewing the ECU carry out all the relevant fault

devices. The devices electrical connections, locations and

finding and diagnostics to confirm ECU failure. Units

wire identifications are given in Electrical Connections -

returned under warranty found not to be faulty will invalidate

Powershift Gearbox - 6 Speed. See also Section C -

any claim.

Harness Data.

If the facilities to use the ShiftMaster Diagnostics software

system are not available, the gearbox and ECU can still be

checked using a conventional multimeter, see Electrical

Connections - Powershift Gearbox - 6 Speed. See also

Section C - Harness Data.

A

A405370

9803/3280

Issue 1

Section F

Transmission

Section F

69 - 1

Service Procedures

69 - 1

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

1. Introduction

2. Care & Safety

ShiftMaster Diagnostics software is a PC based

Diagnostics Tool designed to be an easy to use fault finding

! WARNING

tool for the Service Engineer using a laptop PC. ShiftMaster

Be sure to read and follow any on-screen instructions

Diagnostics employs the graphical strengths of the

issued by ShiftMaster Diagnostics. Failure to follow

Microsoft Windows operating environment to simplify

correct procedure could result in death or injury.

electrical fault finding within the ShiftMaster ECU control

system used on Powershift PS766 6 speed gearboxes.

ShiftMaster Diagnostics is only intended for use with the

ShiftMaster ECU and does not support older versions of

Powershift Controllers used on the PS750 series gearboxes.

To utilise any supporting ShiftMaster Service Tools requires

the use of the JCB Data Link Adaptor [or DLA] (717/ 20138)

which is part of the standard JCB Electronic Service Tool

Kit, part number 892/01033.

S404180

S404170

This software is intended for use on IBM Compatible

Personal Computers (PCs) running Windows 9x or

3. Installing ShiftMaster Diagnostics

Windows2000 operating systems but is not compatible with

The ShiftMaster Diagnostics tool is fully integrated within

either earlier versions of Windows 3.x.

JCB ServiceMaster.

All distributed software can be found on Disk 3 (CD3 -

For full instructions on how to install the ShiftMaster

Adobe) of the JCB Technical Information Parts and Service

Diagnostics software please refer to the documentation

CD-ROM set from Issue 19 onwards. This disk is also

which accompanies JCB Service Master.

supplied as part of the Electronic Service Tool Kit. Copies of

this CD-ROM can be purchased from JCB Service.

If you have successfully installed ShiftMaster Diagnostics

Alternatively, in due course software will become available

but are experiencing difficulties with getting your PC to

for download over the internet via JCBs' Techweb service.

communicate with an ECU then there is a Troubleshooting

Please refer to the available software for full installation

Guide built into the ShiftMaster Diagnostics Help menu.

instructions.

9803/3280

Issue 1

Section F

Transmission

Section F

69 - 2

Service Procedures

69 - 2

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

4. Starting ShiftMaster Diagnostics

This document assumes that JCB Service Master has

Step 2: Connect the 'Machine Cable' between the DLA and

already been installed.

the machines' Diagnostic Connector. The 'Machine Cable'

has a 15-way D-type connector on one end and a 9-way

Step 1: Connect either the 'Serial PC Cable' (717/20138) or

CAN connector on the other. Plug the 15-way connector into

the 'Parallel PC Cable' (721/11071) between the DLA and a

the DLA and tighten the thumb-screws, then connect the 9-

free port your laptop computer.

way CAN connector into the machines' Diagnostics

The 'Parallel PC Cable' has a 25-way D-type connector on

Connector A and twist the lock-ring to secure it.

both ends or the lead.

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The 'Serial PC cable' has a 9-way D-type connector on one

end and a 25-Way D-type connector on the other.

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Plug the 25-way male connector into the DLA and the other

connector into a free port on your laptop PC, remembering

to tighten any thumb-screws appropriately.

D

C

E

B

A

F

J

G

H

A

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Step 3: Turn ON the machine ignition and additionally start

the engine if required (taking normal precautions).

Note: Be sure to follow all the cautionary notes given earlier

and those which accompany the software.

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Section F

Transmission

Section F

69 - 3

Service Procedures

69 - 3

Powershift Gearbox - 6 speed

ShiftMaster Diagnostics - User Guide

Step 4: Start JCB Service Master. And go to the BHL

Connection Problems:

section.

ShiftMaster Diagnostics will start and can be partly used

even if there are connection problems.

In general, whenever there are problems communicating

with the DLA there will be an error message displayed.

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More specifically, if communications can not be established

with the DLA then the ECU Setup Page will display 'NO DLA

COMMS' where the ECU Part Number should be.

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Step 5: Start the diagnostics tool running by clicking on the

ShiftMaster Diagnostics icon.

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If communications can not be established with the ECU then

the ECU Setup Page will display 'NO ECU COMMS' where

Step 6: The ShiftMaster Diagnostics tool will then open up

the ECU Part Number should be.

displaying the main window as shown here.

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Note: The ECU must be powered for communications to

work, i.e. the machine ignition must be ON (but the engine

need not be running).

For further details on possible communication problems

please consult the Troubleshooting Guide included in the

Help menu.

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Step

7: To start the ShiftMaster Diagnostics tool

communicating with the ShiftMaster ECU either

click on the Start button or select Start Diagnostics from

the Options Menu. (See later sections for full details.)

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